Gives an elaboration of the systematic design approach on a practical level, i.e. the redsign of a fire hose reel. Describes the redsign process from the problem definition phase to the detail design phase. Looks at methods and techniques used during the design process and presents the design results of every phase from design specification to the relevant details of the new design. These design result have been used in the frequent communication between the client and the external engineering bureau Stevens & Van Vreeland. Gives special attention to the DFA‐method because assembly is a very important aspect (cost saving) for this product. Analyses and compares the old and new product using DFA. The advantages were to show explicitly (in terms of costs and assembly time) the obtained improvements, to optimize details in the new design and to invent some efficient assembly methods and tools. Finally shows the achievement of a reduction of assembly costs of approximately 50 percent.