Business Stakes
- Strategic decision: build in-house vs continue buying external
- Production line efficiency gains
- Potential new product line for sales to other manufacturers
Project at a Glance
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Challenge
- Parts from different brands
- Limited customization control
- User needs unclear
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Constraints
- Stable yet transportable
- Cleanroom compatible
- Front-access maintenance
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Approach
- Operator floor research
- Pain point analysis
- Platform architecture
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Impact
- Complete concept package
- Trade-offs documented
- Stakeholder visuals
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The Challenge
Prodrive Technologies was evaluating whether to develop their own PCB conveyor system rather than relying on external suppliers. The goal: more control over their production line and potential product to sell to other manufacturers.
Before committing engineering resources, they needed to validate if an in-house system was feasible and actually better than existing solutions.
Problem
- Conveyor line consists of parts from different brands
- Limited control over customization and future modifications
- Multiple specialized configurations required (scan units, cooling stations, inspection, reject stations)
- Unclear if user needs could translate into manufacturable design
The Stakes & Constraints
Technical Constraints
- Stability: Heavy enough not to move when leaned against, yet transportable with standard pallet wagon
- Manufacturing scalability: Platform must support multiple unit types (basic, scanner, cooling, inspection) from common base
- Maintenance access: Electronics accessible from front (units often placed against walls)
- Cleanroom compatibility: Cable management, easy cleaning, smooth surfaces
Phase 1: Understand the Real Problem
Started with on-floor operator research rather than jumping to CAD.
Method
- Analyzed provided requirements list
- Conducted short interviews with PCB conveyor operators on production floor
- Observed actual usage patterns and pain points
Key findings from operators
- Operators want leg room when sitting at conveyors for extended periods
- Operators improvise solutions (tape to prevent light reflection, added weight for stability)
- Conveyors move when operators lean against them and realignment is time-consuming
- Need visual confirmation of PCB location in conveyor (or indicator when PCB present)
- Scanner covers create access problems. Operators need hands free when carrying PCBs
- Flat scanner covers become storage surfaces, making access difficult
Clutter on flat surfaces.
Black ducttape to prevent light reflection.
Hard to see if there is a PCB.
Cable clutter.
Leg room required.
Phase 2: Design Decisions and Concept Drawings
Translated operator insights into platform architecture.
Platform approach: Common base architecture with unit-specific tops. This allowed different configurations (basic, scanner, cooling, inspection) to share tooling and assembly processes while meeting distinct functional needs.
Key Decisions
1 Prioritized operator ergonomics
Single-side pallet wagon access was sufficient for installation logistics, but lack of leg room affected daily comfort.
2 Dark interior surfaces eliminated light reflection
No more ducttape needed.
3 External cable ducting for clean appearance and maintenance access
4 Front removable back panel to access cable ducts
5 Sloped upper surface to discourage clutter
Base conveyor unit
Scanner unit
Phase 3: CAD and Rendering
Base unit in SolidWorks and first render
SolidWorks CAD model
Assembly line render
Result
Prodrive's mechanical design department received a complete concept package ready for detailed development.
Impact
1
Complete Concept
5
Design Decisions
∞
Operator Insights
Delivered
- Operator insights translate to engineering specs. Real production floor problems (stability, ergonomics, improvised fixes) became concrete design requirements that engineering could work with.
- Trade-offs were documented. Decisions like prioritizing ergonomics over two-side pallet access were recorded with rationale, giving stakeholders clear understanding of design choices.
- Concept visuals to show stakeholders.