Technical
The swing out centre units, originally developed for the golf market, were considered an unmet need
A Jacobsen Beta prototype
adding more weight to accommodate the swing-out arm mechanism. Using the Alpha mule, our design engineers devised some ingenious patented design solutions to overcome the
problem. using existing components and modular design elements.
Alpha prototypes are really used for feasibility purposes, to validate the functionality of the machine, to ensure that it does what it should do, and that it can be manufactured easily when it eventually goes into production. We have some components made by suppliers, and we also constantly review our VOC and the design brief to ensure that it meets and satisfies customer needs and wants. At this stage, we produce these early machines using only prototype tooling.
Returning to the swing-out centre unit on the Highway 3; this was developed at Alpha stage using its larger predecessor, the Highway 2130 as a mule. The design brief for the Highway 3 was to produce a municipal triplex with all the benefits of the Highway 2130, but in a smaller, lightweight package, allowing it to be transported on a 3.5 tonne truck. The main issue was that we wanted to build something lighter, but had to begin by
Having tested the feasibility and functionality at Alpha stage, we can now progress to build the Beta versions.
Beta prototypes
Beta prototypes are now nearing something approximating to the finished product. They incorporate all the changes agreed during Alpha build with input from suppliers, trusted end users, selected dealers and distributors and our sales team.
They are built on a production line in our manufacturing plant to determine that they can be fabricated successfully in this environment. At this stage, our assembly team will report any manufacturing issues to product management and these will be resolved with the director of manufacturing. Using a mix of prototype and production tooling we build up to six Beta units, which are then used for extensive testing.
Testing
Some of these Beta units will go onto our circular test track, where they will be run 24/7 over obstacles to test durability; others will be put onto test rigs for
repetitive lift and lower tests, vibration tests and load tests, all to simulate five years of use.
Some will be sent out for field testing with trusted end-users. These end-users will be asked to sign confidentiality agreements and will test the machines under typical working conditions.
From this testing, we will determine if we have any major issues; if we do, then we will have to re-work some of the engineering and re-test but, assuming we have only minor amendments, we can proceed to the final Gamma stage.
Gamma Pre-production models
At this stage, we will incorporate all the minor refinements resulting from our test programme and build multiple units. This will normally be 6-8 weeks ahead of the launch date and four months before production begins in earnest.
The Bill of Materials (BOM) - every item that is needed to build the machine - will be confirmed and, from this point in, we are committed to production. Parts manuals will be prepared, training manuals for technical and sales staff will be produced and marketing activity will begin, but more of this process will be the subject of our final article in this series.
A Beta prototype on the circular test track 116 PC FEBRUARY/MARCH 2013
Drive off ramp in the test area
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