BRD CONSULTANTS WELCOMES YOU a house of Engineering Consultancy...

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1 WELCOMES YOU a house of Engineering Consultancy... CONSULTANCY FOR REVERSE & REDESIGN ENGINEERING PROJECTS concept to commissioning

2 A house of Engineering Consultancy... Page 1 of 13 ABOUT US is a team of Technical Personnel, mostly Engineers from various disciplines having long experience & skill in engineering projects with special focus on projects in Iron & Steel, Power, Mining, Infrastructure, Utility Services & Pipings, Civil & Structures, etc. Reverse Engineering is a Concept widely used World Wide to reinvent an existing part, called upon to do so either due to lack of original design data or financially responding to market demands. This kind of inquiry engages individuals in a constructive learning process about the operation of systems and products. We provide Cunsultancy on Reverse Engineering & Redesigning as per requirements of a Client, and also support from Concept to Commissioning.

3 A house of Engineering Consultancy... Page 2 of 13 The Concept: The practice of reverse engineering usually consists of two phases: (1) decoding the original design details with appropriate analysis, and (2) reproducing an identical counterpart. The most challenging technical tasks in both phases are directly related to manufacturing processes because the prior history or trails of many manufacturing processes are erased in the final product. The Society of Manufacturing Engineers (SME) states that the practice of reverse engineering is, starting with a finished product or process and working backward in logical fashion to discover the underlying new technology

4 A house of Engineering Consultancy... Page 3 of 13 Why YOU should go for Reverse Engineering? Some of the important reasons for the for reverse engineering of a product or a part are; The original equipment manufacturer (OEM) of a product no longer produces a product OR no longer exists. Sourcing spare part from OEM is not cost effective. There is inadequate documentation of the original design. The original design documentation has been lost or never existed. Some bad features of a product need to be designed out. For example, Excessive wear might indicate where a product should be improved. Failure analysis for repetitive failures of a product or component. Spare parts are not durable. To repair a worn-out part without the original design data or any spare parts available. To analyze a competitor s part for business advantage. Reverse engineering contributes to a multi-billion-dollar spare parts aftermarket annually just in the aviation industry alone. To study an existing part or machine for research or academic purposes. For example, to search for the optimal reinvention of an automotive truck to meet the ever rigorous emission standards, hundreds of parts and components that interact with one another might have to be studied for modification. Reverse engineering can significantly reduce the model building cycle, and drastically save prototyping costs by starting with an existing obsolete non-compliant model as a base to develop the new model. To update obsolete materials or antiquated manufacturing processes with more current, less-expensive technologies

5 A house of Engineering Consultancy... Page 4 of 13 Major Components of Reverse Engineering In order to reverse engineer a product or component of a system, engineers and researchers generally follow the following four-stage process: Identifying the product or component which will be reverse engineered: In the first stage in the process, sometimes called "pre-screening," reverse engineers determine the candidate product for their project. Potential candidates for such a project include singular items, parts, components, units, sub-assemblies, some of which may contain many smaller parts sold as a single entity. Observing or disassembling the information documenting how the original product works: The second stage, disassembly or recompilation of the original product, is the most time-consuming aspect of the project. In this stage, reverse engineers attempt to construct a characterization of the system by accumulating all of the technical data and instructions of how the product works. Implementing the technical data generated by reverse engineering in a replica or modified version of the original: In the third stage of reverse engineering, reverse engineers try to verify that the data generated by disassembly or recompilation is an accurate reconstruction the original system. Engineers verify the accuracy and validity of their designs by testing the system, creating prototypes, and experimenting with the results. Creating a new product (and, perhaps, introducing it into the market): The final stage of the reverse engineering process is the introduction of a new product into the marketplace. These new products are often innovations of the original product with competitive designs, features, or capabilities. These products may also be adaptations of the original product for use with other integrated systems, such as different platforms of computer operating systems.

6 A house of Engineering Consultancy... Page 5 of 13 The entire process of Reverse Engineering pass through three crucial milestones, which determine the success of reverse engineered product. These are: Material composition identification Part dimension (geometric shape & form) determination Verification of manufacturing process SUCCESS OF REINVENTING A PART BY REVERSE ENGINEERING DEPENDS ON MATERIAL COMPOSITION IDENTIFICATION PART DIMENSION DETERMINATION MANUFACTURING PROCESS VERIFICATION

7 A house of Engineering Consultancy... Page 6 of 13 BottleNecks The two primary objectives of applying reverse engineering in manufacturing are to reinvent a part for market competition or for part restoration. Technically both these objectives heavily rely on the success of three key elements: material composition identification, part dimension determination, and manufacturing process verification. Material composition identification with 100% certainty is beyond our reach; however, most of the time engineers can determine the material composition with reasonable acceptance from a manufacturing perspective. Part dimensional data can usually be precisely regenerated with advanced modern metrology. The most challenging task is to verify the detailed manufacturing parameters. Modern analytical technologies such as quantitative metallography and residual stress measurement have made it relatively easier to reveal some prior history of a manufacturing process. Nonetheless verifying the complete manufacturing process of a part can still be a complex and somewhat clueless task, such as, the verification of the temperature, cycle, and time duration of a heat treatment process. One way to decode a heat treatment process by reverse engineering in manufacturing is to verify as many parameters as possible, and then select the best probable heat treatment process following the material specifications commonly used in the manufacturing industries

8 A house of Engineering Consultancy... Page 7 of 13 Modern analytical technologies like quantitative metallographic and residual stress measurement OUR TEAM HAS RICH EXPERIENCE IN Ensuring proper heat treatment process for the reproduction of a reverse engineered part Effective methods to compare microstructure between the original and the reinvented part.

9 A house of Engineering Consultancy... Page 8 of 13 Our services: Systematic evaluation of a product / Sub- System for replication Preparation of QAP, stage & Final Inspection Supports for Redesign & Reverse Engineering of Sub-Process / Components OUR SERVICES INCLUDE Supports with Vendors, Procurement & Installations Import substitution with Indian equivalent Supports with Design, knowhow of reverse engineered parts

10 A house of Engineering Consultancy... Page 9 of 13 Integration of Reverse Engineering with CAD The reverse-engineering process needs hardware and software that work together. The hardware is used to measure an object, and the software reconstructs it as a 3-D model. The physical object can be measured using 3-D scanning technologies like a coordinate measuring machine, laser scanner, structured light digitizer, or computed tomography. Integrating Value Engineering with Reverse Engineering We introduce the combination of Reverse Engineering and Value Engineering which is profession involved in designing, manufacturing, constructing, and maintaining of products, systems, and structures. The concept of Value Engineering allows Reverse Engineers to suggest alternatives to materials, equipment, or even designs provided by the design professional that can save the owner money in up-front or long-term maintenance costs. Use of Reverse Engineering has been applied in more industries and in different projects by considering the complexity and high level of technologies in products. Optimum Value Engineering is the process of comparing alternative materials and methods to determine the least costly combination that will result in the desired end product.

11 A house of Engineering Consultancy... Page 10 of 13 WE AND OUR STRENGTH Sound Engineering Knowledge Emphasis is given in our organisation to update the knowledge and professional skills of our Engineering team. We encourage use of latest technological advancements in every field to achieve functional,economical & safe designs. Our engineering team possesses quite a good field experience too. They are capable of handling difficult engineering problems and taking on the spot decisions. They are highly motivated and are committed to quality. Quality Drawings Drawing is the primary medium through which a Consultant directs the people on site. So, it is absolutely necessary that the drawing is complete in all respects and all the relevant information is furnished explicitly and clearly on the drawing by way of illustration or otherwise. While preparing drawings emphasis is given on elaborate and precise detailing. Even minute details are worked out and illustrated. Nothing is left to the discretion of site people to err. A thorough checking of each and every drawing is a part of our continuous endeavour to enhance the quality of service rendered. We strive for Better Service through Implementation of appropriate working standards, systems, and procedures. Hunting for ways and means to continually improve the performance on our jobs and goal setting for increased effectiveness and innovation. Identifying "lessons learned" through feedback mechanism and focusing on prevention rather than on correction. Imbibing amongst the team members the importance of realistic, rational and positive approach. Team work Building trust, creating a real project 'team' that includes all the principal players dedicated to the same goals is what makes the projects successful. The success of any project depends to a large extent upon the motivation and the commitment of the project team. Our real strength lies in our highly motivated and committed engineering team. supports extensive use of computer workstations, to expedite the various architectural and engineering design processes. The incorporation of latest software techniques to ensure, accurate detailed and faster drawing schemes for the Client. Our working utilises latest softwares like AUTOCAD, STAAD PRO as per requirements, to ensure faster and accurate design & drawings.

12 A house of Engineering Consultancy... Page 11 of 13 Our Technical Expertise: KEY PERSONNEL PROFILES GURUDEO KUMAR YADAV SR. VICE PRESIDENT & PROJECT DIRECTOR (TECHNICAL) Shri Gurudeo Kumar Yadav has been General Manager in HEC Ltd, Ranchi (Jharkhand), India, CPSU, under Ministry of Heavy Industries, Govt. of India. Shri Yadav, a Master in Technology in Metallurgical Engineering, has rich experience in Material Selection, Casting, Forging, Heat Treatment, Technology Development, Failure Analysis etc He has many prestigious projects to his credit including manufacturing. Supply, erection and commissioning of Continuous Casting Machine at Rourkela Steel Plant (RSP), modernisation of various units of Nilachal Ispat Nigam Ltd (NINL). Shri Yadav has successfully discharged his responsibilities as head of Forging, Heat Treatment Electro-plating & Reduction Gear shop of HMBP. Foundry Forge Plant (FFP), HEC Training Institute. Shri Yadav and His team have long Experience & Skill in metallogarphy and manufacturing processes.

13 A house of Engineering Consultancy... Page 12 of 13 OUR CORE MANAGEMENT A V KRISHNA PRESIDENT Shri Krishna, Ex DIRECTOR (MARKETING) from a CPSU, HEC LTD., carries rich experience of business development in the engineering and aviation sectors. As a whole time Director of a schedule A CPSE,namely Heavy Engineering Corporation Ltd, Ranchi he had opportunity to promote the marketing of heavy machineries to the mining, steel, defence and strategic sectors. EPC projects worth around Rs 1900 crore for the steel and mining sectors progressed well under his guidance. He also carried forward the HR functions at an accelerated pace to pitchfork the employee motivation level. In order to improve the standard of aviation services at Ranchi massive modernisation and expansion programme of the airport was planned and embarked upon when he was the Airport Director. Ranchi now boasts of a world class airport terminal and is poised to have a 9000 ft runway. He managed the operations of communication, navigation and surveillance facilities in the eastern and north eastern regions airspace. He has to his credit the planning for installation of instrument landing system at a number of otherwise difficult airports. He represented the country at International Civil Aviation Organisation meeting regarding certification of radio navigation aids. After this curtain raiser, an international assignment on certification of navigation facilities in the neighbouring countries, A UNDP project, was embarked upon with the full confidence of service receivers. He started his career with state electronics development corporation looking after business development in the mining electronics area. Subsequently he joined Govt of India on being selected through Engineering Services Examination RAJ KUMAR GARG JOINT PRESIDENT Shri Garg, Ex GENERAL MANAGER (COMMERCIAL) from a CPSU, MECON LTD., A Mechanical Engineering Graduate, has about 36 years of experience of working with premier Consultancy organization under Ministry of Steel, Govt. of India, engaged in rendering its services for establishment, modernization and expansion of various integrated Iron & Steel Plants for public as well as private sectors of Indian industries, infrastructure projects, projects in oil and gas industries. Out of total experience, experience of about 13 years in the field of procurement services, commercial and contracting functions, heading an expert team of Commercial and Contracts division of the Organization engaged in Consultancy as well as EPC projects for various industrial sectors, WB / MDB Funded projects, with unlimited commercial and contracting responsibilities, has gone long way in gaining understanding of various clients requirements to steer the projects to success. This experience has also given an indepth insight of strength and weaknesses of various vendors and clients. Earlier experience of about 23 years of working at various sites as mechanical engineer with responsibilities of execution and supervision of erection, testing, commissioning in various capacities of various utilities, services and technological plants, not only laid a strong base foundation of knowledge and skills but also provided a rich experience which made understanding of commercial and contracting responsibilities requirements associated with execution of various industrial projects at later stage, as head of Commercial Division of the organization, much easier.

14 A house of Engineering Consultancy... Page 13 of 13 CONTACT DETAILS Our President: Shri A V Krishna : Our Joint President: Shri R K Garg: Address: D-1B, GREEN GARDEN, HESAG, RANCHI , (JHARKHAND), INDIA FOR FURTHER DETAILS VISIT OUR SITE: