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PRODUCT DEVELOPMENT
• 250 Engineers•100 Design Engineers• 80 R+D Engineers• 70 Test Engineers and Technicians
PRODUCT DEVELOPMENT• R+D Engineers include:
• Fluid• Mechanical• Electrical• Electronic• EMC• Thermal• Chemical• Material• Acoustic• Software
PRODUCT DEVELOPMENT
• Design Engineers split into project teams• Typical project team (ie DC05)
• Project Manager• Senior Design Engineers (x2)•Design Engineers (x6)• Quality / Purchasing / Production (x2)
PRODUCT DEVELOPMENT - DC05
• The Brief:• Smaller• Quieter• More Powerful• Lighter
PRODUCT DEVELOPMENT - DC05
• Initial Concept Phase•Establish building blocks
• Bin capacity• Motor size• Cable reel• Filter size
•Cardboard modelling / sketching• 20+ configurations modelled in first 3 weeks
PRODUCT DEVELOPMENT - DC05
•Final Concept Phase•Balance rigs / Breadboards - prove machine handling• 2D mechanism models - structure and operation•CAD modelling (to support model building)•All major parts identified
•BOM cost•Tooling Estimates
PRODUCT DEVELOPMENT - DC05
• First working prototype - prove out theories• Suction power• Noise• Cyclone performance• Blockages
PRODUCT DEVELOPMENT - DC05
• Cyclone Development• R+D fluid dynamists provide expertise
• Cyclone Geometry• Filter requirements
• Design Engineers• Interpret and package in to product• Testing in product• Iterative development
PRODUCT DEVELOPMENT - DC05
• Blue foam - visual check• Handles• Actuators• Visual detailing
PRODUCT DEVELOPMENT - DC05
• Detail design - CAD intensive phase• Part interaction• Fits and assembly• Tooling - design tools
• Rapid prototyping - (in house FDM 2-3 models)• First dimensionally accurate and functioning model• Check machine operation• Performance testing
PRODUCT DEVELOPMENT - DC05
• Rapid prototyping - SLA Resin cast / SLS (15 machines)
• Accurate performance data• User trials (UK and International)• Mechanical testing
• Abuse testing• Repeat actuation
• Standards and approvals
PRODUCT DEVELOPMENT - DC05
• Tooling• Capital commitment (1 million pounds)
• First moulded samples - “T1” • Engineering build
• Prove fits and assembly• Machine operation / performance• Testing
• Iterative loop, Tooling modifications and T2
PRODUCT DEVELOPMENT - DC05
• Production Phase• Pre production build
• Train production team - on line• Prove assembly with production volumes• Test for final product validation
•Start of production - pipe fill• Engineering team into Current support• Trouble shooting production issues• International variants • Cost down