This post deals specifically with the form, fit and function method of reverse engineering. This is a general methodology and a good starting point. A more specific methodology may be needed for specific types of projects. Reverse engineering is an important process in Lean Six Sigma. We may not call it reverse engineering, but that is what it is. Please bear in mind that this post is a general, not a detailed, description of this methodology.

There are areas of overlap in a form, fit and function analysis. This is the natural result of moving through the form, fit and function steps in the analysis process. Additionally, the steps are cyclic in that the analysis is repeated with increasing levels of detail. This “drilling down” to more granular knowledge of how something works, or should work, allows for a more robust design of a new, or refined, product or service.

At the core of this analysis process is the strategy of documenting what you know separately from what you assume. The purpose of the next cycle of analysis is to move assumptions from the assumed category to the fact category (or eliminate them). At the end of each cycle, there will be an increase in what is known and a new set of assumptions for the next cycle. Assumptions stay assumptions until they are resolved to fact or eliminated.

The form, fit and function analysis is similar to a forensic analysis of failures. The steps may have different names, but the drilling down process is the same. The key is to avoid errant leaps of logic that lead to incorrect conclusions. The analysis is repeated at increasing levels of detail, as the detail is discovered. The analysis moves us from assumption to fact.

You will notice that the questions in each category below are framed around the interrogative, “What”. To repeat the analysis cycle to gain better detail, the “why” must also be discovered.  A “mind map” is a good tool to use in documenting the progress made in the various analysis cycles.

Form:

• What is the purpose of the product or service?
• What assumptions are built into the design of the product or service?
• What is the assumed skill level of the user of the product or service?
• What other tools or knowledge are needed to use the product or service?
• What is the development history of the product or service? (What product or service does it replace and why?)

Fit:

• In what specific situation(s) is the product or service intended to be used?
• What are the specific capabilities of the product or service?
• What are the specific capabilities lacking in the product or service?

Function:

• Looking at the product or service’s internal processes, what does it do?
• Looking that product or service’s internal processes, how does it do it?

The above questions are a starting point and will get more specific as more knowledge is gained. It is simply a matter repeating the analysis cycle until it makes sense to move forward on a prescribed course of action.

There is a lot more detail to the form, fit and function method of reverse engineering than this post can cover. To learn more, check out my Lean Six Sigma book titled, “Lean and Mean Process Improvement”.