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Redesign methodology for mechanical assembly

El-Nounu, AbdulRahman; Popov, Atanas; Ratchev, Svetan

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AbdulRahman El-Nounu

Professor of Engineering Dynamics

Cripps Professor of Production Engineering & Head of Research Division


Design for assembly is the concept of carrying out critical thought early in the design stage to create assembly easement at the production stage. In the aerospace industry, products have very long lives, frequently being optimised rather than introducing new products. This has meant older products, which are stable income generators, have not benefited from the latest design for assembly methods and manufacturing technology suffers from obsolescence. It has been established that a large percentage of overall product cost is determined at the design stage; thus, existing products suffer from preloaded costs. This paper takes existing design for assembly methodologies and analyses them with respect to the unique challenges involved in legacy product redesign. Several novel factors that contribute to redesign analysis are identified such obsolescence impact and a holistic operation difficulty assessment. A tool is developed to identify potential redesign for assembly projects. The tool is demonstrated through the application of real data and comparing against business decisions. The tool was found to provide a strong indication of where profitable projects may be launched.


El-Nounu, A., Popov, A., & Ratchev, S. (in press). Redesign methodology for mechanical assembly. Research in Engineering Design,

Journal Article Type Article
Acceptance Date Mar 23, 2017
Online Publication Date Apr 3, 2017
Deposit Date Apr 12, 2017
Publicly Available Date Apr 12, 2017
Journal Research in Engineering Design
Print ISSN 0934-9839
Electronic ISSN 0934-9839
Publisher Springer Verlag
Peer Reviewed Peer Reviewed
Keywords Design for assembly ; Redesign for assembly ; Aerospace assembly
Public URL
Publisher URL


art_10.1007_s00163-017-0255-6.pdf (1.1 Mb)

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