PRODUCT DEVELOPMENT

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PRODUCT DEVELOPMENT

• 250 Engineers
• 100 Design Engineers
• 80 RD Engineers
• 70 Test Engineers and Technicians

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PRODUCT DEVELOPMENT

• RD Engineers include
• Fluid
• Mechanical
• Electrical
• Electronic
• EMC
• Thermal
• Chemical
• Material
• Acoustic
• Software

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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)

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PRODUCT DEVELOPMENT - DC05

• The Brief
• Smaller
• Quieter
• More Powerful
• Lighter

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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

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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

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PRODUCT DEVELOPMENT - DC05

• First working prototype - prove out theories
• Suction power
• Noise
• Cyclone performance
• Blockages

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PRODUCT DEVELOPMENT - DC05

• Cyclone Development
• RD fluid dynamists provide expertise
• Cyclone Geometry
• Filter requirements
• Design Engineers
• Interpret and package in to product
• Testing in product
• Iterative development

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PRODUCT DEVELOPMENT - DC05

• Blue foam - visual check
• Handles
• Actuators
• Visual detailing

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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

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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

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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

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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

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