Date: July 4, 2023 1:06 pm

What is Reverse Engineering?

What is Reverse Engineering?

Reverse Engineering Supports Innovation, Business Development and Growth

The simple principle of reverse engineering is to understand how something works.

Dismantling a component or system, will enable knowledge to be gained about its physical structure and function. Understanding how a system works will allow it to be re-created. However, the greatest benefit of reverse engineering is through specialist investigative evaluation, it can improve the system.

Incorporating updated developments and enhancements will provide greater operational efficiencies, improve functionality, safety, as well as reduce costs.

Reasons to undertake reverse engineering include:

  • Controls systems and components become obsolete.
  • Ageing systems that become too costly to maintain.
  • New business demands see control systems unable to meet requirements.
  • The need to develop a control system to generate business efficiencies and growth.

The Need to Use Reverse Engineering

It can be simply because control systems or components are obsolete, and the appropriate spare parts are no longer available. This exposes a weakness in the ability to cost-effectively maintain the system.

An ageing system can place a business at risk.

Retaining an ageing system increases the possibility of system failures causing unscheduled production interruptions and pro-longed downtime. Maintaining an ageing system will begin to outweigh the costs of investing in a new enhanced system.

With the need to constantly meet changing demands. Systems may also start to fall short of reaching all the functions needed to meet new objectives for operational growth.

Reverse Engineering is often needed, due to the result of poor documentation and data handling. Where control systems knowledge has been lost over the years, it can lead to any further works on the system being inefficient and therefore expensive.

For many, reverse engineering is undertaken to evaluate the system or component to further enhance it, to provide a more efficient and cost effective operation.

Manufacturing operations are continuously in need of improvement to take advantage of new technology and innovations, improve productivity, capabilities, performance and to reduce costs.

The basic steps to undertake reverse engineering is:

  • Review and survey the system, to understand the current process, its capabilities, challenges and compliance with current industrial standards.
  • Start the reverse engineering process by accurately mapping the current system.
  • Undertake a feasibility study to illustrate how the system can be developed, to meet the criteria set out and to further enhance the process.
  • Using the information gained and investigational findings, to begin preliminary design of the new automated systems.
  • Map out the system and illustrate the system’s actions to meet required objectives.
  • Detailed system design drawings will be created, to enable the system to be built.
  • Control panels manufactured and site electrical installation.
  • Control systems software development and commissioning.

Reverse engineering will enable the current system to be evaluated and identify the improvements to enhance the operational automation process. Utilising this process can avoid the need for a complete system to be renewed and provide a business with significant savings and improved operations.

Delta Rock: Automation engineering experts in Reverse Engineering for operational efficiency improvements and development.

At Delta Rock we have in-house automation and electrical engineering expertise that can work through the complete reverse engineering principles to deliver operational improvements and efficiencies.

With over 40 years of electrical engineering experience and our in-house automation design engineering team, we have the expertise and capabilities to reverse engineer the most challenging operational processes.

If you need to improve or develop your automation control systems within your production process, to improve efficiencies, reduce downtime, increase productivity, reduce costs, and provide the growth for your business, then talk to the team at Delta Rock.

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