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Reverse Engineering Services for Manufacturer of Refrigeration Compressors

The Client

Our client is a manufacturer and supplier of spare parts for a wide range of refrigeration compressors throughout the UK, Europe and Middle East.

Situation - Business Needs

The client had a specific need of carrying out reverse engineering on fiber gaskets so as to derive solid models in DXF AutoCAD file format. The business need resulted from issues like dearth of skilled resources and budgetary limitations. The client decided to garner and examine offshore possibilities to leverage on the cost advantage from an offshore solution, given that order volumes were significantly high. It also wanted to capitalize on the competency of an outsourcing vendor to streamline its operations and achieve greater efficiency.

The client's business situation entailed:

  • Reverse engineering of hundreds of gaskets according to predefined specifications
  • Shipping the gaskets to an offshore location
  • Deriving error-free true dimensional DXF output of each gasket
  • Using the DXF files to set up shapes needed to cut the gaskets to precision


Some of the key challenges faced during the course of the project were:

  • The gaskets came in various shapes and sizes - adding to the complexity of the job
  • Measuring, analyzing and testing each gasket design meticulously to preserve design intent
  • Providing a true dimensional DXF file accurate to the original in an editable electronic format
  • Working within the budgetary constraints and a stipulated time frame set by the client

The Outsource2india Solution

The project team did a thorough requirement analysis to decide on its approach to the project. The notable components of The Outsource2india Solution included:

  • Laser scanning of a few sample gaskets to get the cloud point data
  • Extracting drawings from the data
  • Converting the scans to DXF files using SOLIDWORKS 2012
  • Getting the samples reviewed and approved
  • Starting work on full order quantity- 500 gaskets- after the client was satisfied with the quality of the samples
  • Using state-of-the-art workstations complete with AutoCAD, SOLIDWORKS and other software
  • Setting aside resources in the form of back up staff and funds to meet project deadlines
  • Deploying backup and disaster recovery systems to prevent downtime
  • Ensuring top-level security of client data by employing rigorous security measures that included:
    • Secure VPN communication - IPSec/PPTP for secure access to files and information
    • McAfee Enterprise Suite for virus prevention and cure
    • HIPS (Host Intrusion Prevention System) and NAC (Network Access Control)
    • Gateway level anti-spyware and spam filter for internet access and mail server
    • URL filter application for surf control
    • Domain level access restrictions along the line of Group Policy
    • Restricted Internet Access based on Domain Authentication
    • Centralized server based storage and File system access policy based in user authentication.


  • The client experienced savings to the extent of 50%
  • Freed up resources and overheads associated with hiring additional staff, and helped the client focus on its core business goals
  • Our solution enabled the streamlining of manufacturing processes resulting in better efficiency
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