Optimized Manufacturing Process Increases Safety While Decreasing Costs

Opportunity:

An OEM purchased an existing cab design in an effort to expand their offerings into new market segments. They approached GS Global Resources looking to revise that design over time, with particular goals of improving safety, manufacturability, and giving the cab a more modern look overall.

Solution:

In an effort to utilize existing inventory, our engineers designed a new version that still utilized the aluminum panels from the initial cab structure with a slightly different controls layout. It repositioned the radio and a few other controls into the b-pillar. This first update primarily gave the cab a fresher look, while still maintaining the original structure.

In the second redesign phase, we were able to eliminate those aluminum panels and replace them with vacuum-formed plastic, giving the cab a much smoother, more modern look. Looking to also improve efficiency within the cab design, GSGR engineers moved to an electrical harness solution. By utilizing a harness and moving to a fuse-relay power module, the cab now has a more compact electrical solution with everything located in a central power block.

Improving safety was a primary goal of the second redesign phase. The original cab was ROPS/FOPS certified at a lower level of 80,000 lbs. Initial analysis showed the original structure was very stiff and required preheating on a lot of weld zones in order to reduce the occurrence of cracking and other issues. While necessary with the original weldment material, it added time and cost to the manufacturing process. Through our subsidiary, ADC Equipment Innovations, we were able to design a much more manufacturing friendly frame, using a more durable material that no longer required preheating. Thanks to these structural improvements, the cab now has a higher ROPS/FOPS certification level at 90,000 lbs, increasing operator safety.

One other considerable safety improvement was the elimination of front and top window guard rails. While originally a safety necessity, they also significantly impeded operator view. By switching the windows to multi-layer laminated polycarbonate glass, we were able to give that same level of protection, while giving the operator a much better view of the application area.

Result:

• Created a more modern cab interior by replacing aluminum paneling with vacuum-formed plastic.
• Improved safety by increasing the ROPS/FOPS certification level and eliminating front and top window guard rails.
• Designed a more compact electrical solution, which is also more accessible for adjustments and repairs.
• Reduced manufacturing costs and time by eliminating the need for material preheating.