Aligning new product development with reverse engineering methodologies for headlamp jig

Abstract This study explores the combination of reverse engineering (RE) and new product development (NPD) methodologies to enhance the manufacturing process of headlamp jigs. RE, utilised as a benchmarking technique, aids in regenerating parametric designs or innovating new product concepts. The distinctive appearance relies on headlamps with protective coatings cured at high temperatures in UV ovens, necessitating jigs capable of withstanding such conditions. Hence, employing RE becomes crucial to fortifying jig performance. While RE often signifies innovation or refinement, the current headlamp jig encounters deformation issues during manufacturing due to high curing oven temperatures and intense water jet cleaning pressures. The absence of an effective NPD approach exacerbates persistent jig deformation challenges. NPD, encompassing stages like idea generation, concept development, design, testing, and marketing, is crucial. The absence of NPD, along with the complexity of RE, could prolong timelines and escalate expenses in bringing marketable products to fruition. This study aims to propose an NPD model for headlamp jigs, leveraging RE methodologies to enhance composite jig fabrication processes. The integration of PDCA methodologies within NPD intends to rectify deformation issues while optimizing manufacturing processes for superior headlamp jigs.