Systematic retrofit design for manufacture - critical component substitution in machine design

Designing to substitute components is a regular activity in the process of improving the function, whether it is planned or the result of a failure of an existing product, assembly or machine. While this may not create an optimal design configuration, it does maintain the continuity of production and economics of the rest of the machine. The replacement of an existing component or components, however, cannot be done in isolation from the rest of the machine. Designing for component substitution or retrofit design needs careful consideration of all the interfacing components as well as some adjacent components, depending on the circumstances. The consequence of not taking into account all the effects of component substitution could potentially lead to detrimental performance or the worsening of the effect intended. This paper describes a systematic approach to retrofit design through a case study of the feasibility of replacing a key set of components in a machine in order to improve its performance.