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The purpose of this paper is to review the fundamental methodology and its development of intelligent disassembly planning research.

Following a brief introduction, this paper first discusses the fundamental problems associated with disassembly planning and analysis. And then considers the role of intelligent optimization methods in the disassembly planning field. This is followed by a summary and conclusion.

Many advances have been made in computerized intelligent disassembly planning research, which is a natural evolutionary result of both traditional solving methodology and much research effort over past two decades. But as yet, some fundamental limitations are also rooted in this computational model‐based methodology.

The paper provides a fundamental review on the development of computerized intelligent disassembly planning research.

In the present paper, a CAD and reverse engineering (RE) methodology has been adopted for the development of a complex assembly of a TFC 280 crane cabin. A different approach has been adopted to eliminate fouling as well as interference with other components of the crane such as boom, gantry, front drum, rear drum, etc. with its cabin. The paper aims to discuss these issues.

A dummy 3-D CAD model of the assemblies has been made using assembly constraints of Master Assembly and then checked for fouling and interference using IDEAS NX 12 to validate cabin design. In fabrication industries, one of the critical challenges is to maintain close geometric tolerances in finished products, which have been taken care of by the use of accurate value of K-factor.

Ergonomics of the re-engineered crane cabin has also been improved by providing rear vision and improvement in operator's forward visibility from 165° to 180°.

The work has been carried out using RE methodology un-used in this part of the world (Jamshedpur, India).