ABB Australia

66kV modular substation

Remote Power Transmission System

The ABB Substation forms part of a standalone power transmission substation system, specifically for transmission and distribution of 66kV High Voltage. It transforms 66kV High Voltage to lower useable voltages in mining, industrial and utility applications.

It is a recognizable, branded ABB product that is safe, aesthetically appropriate, and customizable for modular expansion whilst improving on manufacturability, transport, assembly and installation on site. ABB’s Modular Substation can be installed in remote locations quickly and with minimal labor. It is a product designed to be assembled and tested in a factory environment, transported to site, and erected with minimal assembly.

Read More

A Self contained substation solution with reduced installation time and complexity

The 66kV modular substation is a self contained solution. It can be deployed and installed with reduced need for infrastructure or components that are usual in substation installations.

It has integrated features such as auxiliary supply, Battery and Charger and no need for additional external cabling. Many components and operational features are assembled, tested and commissioned in the factory pre shipping, meaning less time and equipment is required during install and commissioning.

Deployment is faster and easier, it is transported to site and erected requiring minimal labor with minimal extra assembly.

A substation that utilizes, Modularity, flexibility, Adaptability and yet Customization

The 66kV modular substation is a modular design that can adapt to the needs of the customer in both initial selection of features and in deployment. The design allows for the product to be expanded using a modular methodology, in order to customize to specific client requests of optional extras.
It is adaptable and can be installed in many scenarios and configurations accommodating customers’ needs. The 66kV modular substation can compliment or replace existing substations installations, or several can be installed together in completely new builds. Different substation configurations can be achieved using the flexibility of the design.

A substation solution that benefits customers by reductions in time, cost and people for implementation and costs to run and maintain

ABB has looked at the value proposition of the modular substation and the potential savings in time and costs the design has enabled ABB to provide to its clients.
Time: Up to 16 weeks less in commissioning compared to other existing products, including personal resources needed on site to assemble and install
Cost: Over $2 Million in savings to customers compared to other existing products, including reduction in loss of revenue due to facility down time and reduced commission time, personal required to install and reduced serviceability due to a quality product.

A substation solution designed for transport that fits on a flat bed truck

The 66kV modular substation is designed for minimal bulk when transported. It was designed to fit within the proportions of a 20ft shipping container and within maximum statutory dimension for transportation on public road without a permit. This would limit the need for using specialised vehicles to access sometimes very remote locations, a great cost saving benefiting the ABB solution.

The product design facilitates minimal dismantling post factory commissioning, for it to be shipped to site. The transport configuration also secures the substation parts into a neat package that can be shipped on one truck.

A substation that brings brand recognition and visual appeal to a generic product market

ABB is acutely aware, that amongst all providers of substation equipment, there is little differentiation visually between many products in the market. There is little emphasis placed upon the aesthetics or branding of these infrastructure products.

ABB saw an opportunity to do something different and stand apart from similar and competing products. Such a physically large product provides a great opportunity to create a design that is visually distinct and creates increased recognition via aesthetics and effective utilization of branding. ABB is a world leader and provide “power and productivity for a better world”. The product should reflect this.

By ||Comments Off

Orica

LOADPlus™ Underground Controller

HMI and Graphic User Interface

The LOADPlus™ is a control system for the delivery of explosives (in the form of emulsion) in underground and aboveground mining operations.

The LOADPlus™system has been designed to automate the loading of holes for development and production blasting, delivering explosives faster, more accurately and efficiently. The ruggerdised system is used in operating scenarios from elevated work platforms underground, exposed to falling rock, acidic water and corrosive substances to above ground operations prone to extreme temperature ranges. The outcomes are more efficient, reliable and accurate loading and more predictable blast detonations which improve the safety and production capabilities of mines worldwide.

Read More

Accurate Blasting and Delivery

The LOADPlus™ system controls the operation of pumps, valves, hose pushers and other devices via a CAN (Control Area Network). The enclosure links to the network via a custom connector which also supplies power to the device.

Rock blasts information is planned by engineers using Orica’s Shot Plus software, which is then uploaded to the LOADPlus™. The pre-programmed information specifies the appropriate volume and speed at which explosive product is delivered to the hole to optimise the blast’s effectiveness. The system considers pump rates and calibration data to improve reporting to mine managers and increase the accuracy of blast planning.

Ruggerdised Enclosure

The LOADPlus™ has been designed for rough use in extreme environments while still allowing operators to program precise settings. The LOADPlus™ incorporates a CAN based control system and keypad into an environmentally sealed and vented enclosure.

The design includes a spring loaded cover over the screen interface – when closed it protects the screen while not in use, and when open it serves as a protective hood to shield the display from rocks and debris. A clear PU screen cover protects the control system from explosive emulsion and dirt buildup. The entire enclosure can be easily disassembled within minutes for servicing.

SCR011- Production

User friendly interface

A user orientated design process saw designers at the rock face working with operators and interviewing stakeholders. The goal was to convert a highly technical system into a simple to understand, graphical user interface for the LOADPlus™ system.

A work flow and graphic layout was developed, targeting a reduction in hole loading times and increasing control over loading parameters. The visual layout, design, colour definition and luminosity of the interface considers the wide range of working environments where the LOADPlus™ is used, delivering better clarity and usability, minimal training time and ensuring safe operation of the mining equipment.

Articulated Mounting Arm

Commonly used from an elevated work platform in underground mining environments, the articulated mounting arm has been designed to quickly and easily secure the LOADPlus™ enclosure.  The adjustable arm provides the correct interaction angles for all users, which includes a growing number of female operators.

The simplified cam latches allow for large, gloved hand operation and is resistant to damage which may be caused by dirt, mud, small rocks, or explosive emulsion. It also stops accidental removal if locking has not been completed. The mounting head allows the LOADPlus™ enclosure to be easily docked and enables 360° rotation.

By ||Comments Off

Maxtrax MkII

MKII

Vehicle Recovery Device

You’ve been driving off-road, somewhere isolated and remote. You’re alone, and now you’re stuck. You’re bogged hard and help is miles away. It’s all up to you. What now?

Brad McCarthy founded MAXTRAX in 2001 after hearing one too many stories of this potentially life threatening situation. When we first started talking to Brad, he was looking for a simpler way for one person to extract their bogged vehicle. From that partnership was born the MAXTRAX MkI 4×4 recovery board. This innovative product created an entirely new way of self-extracting your bogged vehicle, and a new market category as well.

Read More

By 2009, Brad and the market-leading MkI product had led MAXTRAX to a national reputation for quality design, engineering, manufacture and service.  The MAXTRAX product range commanded a premium price, and serious users were more than happy to pay. However copycat competitors were starting to enter the market MAXTRAX had created, pushing lower quality solutions at cheaper prices.

In the best design projects, there’s no “us” and “them” – no divisions between consultant, client and the client’s customer. It’s about forming one design team. We were fortunate to have always had this relationship with Brad. The trust there allowed us to explore some tough questions together. Have we created a market for others to take? How do we continue to out-innovate these new low-cost competitors? How could we design a complete solution and experience, not just a board? We started this journey asking how we could save lives in challenging environments. How could we design a solution for the most extreme environments? Who might be the most extreme users we could design for? What about a special forces unit?

The Challenge

Design a next generation recovery board product to help MAXTRAX to protect and extend its market leadership position. Defend Australian market share from low cost competitors, and build an offering to expand into international markets.

The Journey

In order to help MAXTRAX extend its market leadership position, we focussed the development of the MkII product range on the needs of extreme users and extreme environments. We knew if it met the needs of extreme users it would surprise and delight recreational four wheel drivers.

By strengthening MAXTRAX’S positioning at the top end of the market, we would ensure MAXTRAX remained the first choice aspirational brand, leaving the low-end competitors to continue to compete amongst themselves on cost.

To truly understand the needs of extreme users, we built R&D relationships with the best in class – the Australian Defence Force and Australia’s Team Isuzu Dakar racing team. You can’t get much more serious than these guys. These relationships were invaluable not only for the critical insights we developed together, but also for the serious credibility it built for MAXTRAX in these markets.

Maxtraxt-Vehicle_Recovery_Device-Content-660X320-01

For both the Army and Dakar users, speed was critical. When you’re bogged in enemy territory, seconds count. Not just speed in terms of how quickly the board works, but also for how quickly you can find the board, deploy it, use it, put it away, clean up and get going again. This was all about interaction between people and object in pressure situations, and we got numerous insights into how to improve.

Sometimes in design it’s about supporting the surprising workarounds your customers have adopted to extend a product into areas you hadn’t anticipated. One surprising revelation was the Army was rigging together several MAXTRAX boards together into long strips. They often travel in convoys, so when they got to troublesome terrain they didn’t want boards – they wanted temporary roads. This insight led to the development of linking straps and sand peg accessories.

We combined these insights with the years of customer feedback MAXTRAX had been collecting. We quickly realised the MkI product was fairly one dimensional – it was all about functionally getting a vehicle out when it is stuck. But what about before and after that? What about afterwards when your hands are covered in mud? What about storage? What about using the board to dig enough dirt out of the way so you can deploy it in the right spot?

To respond to these needs, we needed to design much more than a board. So we designed the MkII to be a complete vehicle recovery system that considers all of a user’s needs throughout the product lifecycle. It includes a roof rack storage pod, vehicle mounting kits, multi-board linkage straps, accessory pegs, all stored in a package that holds 11 litres of water in case of emergency (or maybe you just want to wash your hands).

How stuff feels matters. Ergonomics matter. Especially when the pressure is on. We significantly improved the ergonomics of the board so it just plain feels better to use. We wanted to make sure it felt right and worked effectively to a casual user, not just to the rough hands of a tradesman or military officer. But you can bet those guys appreciated the difference too. We’ve greatly improved the ease of labour intensive tasks like using the board as a shovel and then pulling it back out of the mud.

Maxtraxt-Vehicle_Recovery_Device-Content-660X320-02

The Outcome

The MkII product range was launched internationally in 2010 at SEMA, the largest Automotive Accessory show in the US. Since this incredibly successful event, great product and good business strategy has seen MAXTRAX’S grow internationally with global distribution partners. Significant military contracts have been filled and in 2013 the majority of professional Dakar Race teams use MAXTRAX as their preferred extraction system.

MAXTRAX remains the undisputed market leader.
We’re not done yet.

By ||Comments Off

Virgin Australia

Self Service Lounge Entry SCANNER

Unit Furniture and Graphic User Interface

The Virgin Australia self-service lounge entry kiosk is a guest facing interaction point that facilitates self-service entry to the Virgin Australia lounge. Guests can gain access by swiping or scanning membership cards.

Read More

A key objective of the design brief was for the form and materials used in the product to integrate into the aesthetic language already developed in the lounge and work across all Virgin Australia lounges, whatever the layout or configuration.

A modular and configurable design solution was also required so that the unit could either be mounted to the foyer pillars or attached to a custom free standing floor plinth with minimum changes.

The design team faced internal cable management, electrical and thermal convection challenges to ensure the unit footprint was kept to a minimum and didn’t create a unit with an imposing and static appearance.

DuPont™ Corian® was applied to the main interface panel and the front fascia panels. Corian® chosen as the material of choice for its high quality look and feel, outstanding durability as well as ease of maintenance and cleaning, plus it can be easily machined and thermoformed.

The tactile qualities of Corian® were also an important factor in the choice of material as the kiosk is often the guest’s first touch point as they enter the premium lounge experience.

By ||Comments Off

Babyhugs

lullabub

Cot rocker

What’s the price of a good night’s sleep?

“Exhausted and confused, we were desperate for sleep and were simply not sane. We argued all the time, it almost destroyed our relationship”. Any parent of any child will tell you that sleep deprivation is the biggest issue with very young children. When your child is a poor sleeper It affects everything. In the words of one mother we interviewed “…its a slow form of torture“.

Read More

A partnership for peace

Chris Mitchell did not own a product company; his company built homes. He approached us with a simple, very human problem; his child would not fall sleep unless driven around in a car. His next question you can probably guess – how do I bottle the car-driving magic and use it on demand at home to get my baby to sleep? We wanted to know that one too. Several of us had our own young screamers. Chris, like the rest of us, had an intense personal connection to the problem, but he also realised there was a much bigger opportunity if this need could be met. So – bring peace to our own families, and to a whole bunch of other families too? We were pretty excited.

How do people deal with sleepless babies?

The world of sleepless babies is a scary and confusing place. Why, oh why, won’t they just go to sleep? What are the causes? What are the effects? What solutions are out there? Simply put, how do people deal with babies who just won’t sleep?

So what did we learn? There is a colossal amount of information on this subject. Everyone has their own tricks, their own family secrets handed down through the generations. We explored everything from controlled crying to chiropractics. We carefully approached SIDS, which was a huge area in its own right. We performed research. We talked to parents, doctors and health care workers.

The proposed initial solution of simulating a drive in the car sounded promising. And boy does it work. But why does it work? How? We needed to understand it if we wanted to replicate it. We did try just having a car in the bedroom, but for some reason there wasn’t too many people who liked that option.

After much consternation we discovered the secret – low frequency vibration. Any source of low frequency vibration would help to put a baby to sleep. It is vibration, not sound that is most influential in lulling babies to sleep. Could it be that it was as simple as simulating the feeling of a mother’s heartbeat against a child’s face?

The secrets of a mother’s heart

Vibration, heartbeats. Got it. But how could we apply that feeling to a cot? How do we get a cot to vibrate and have it feel like a mother’s heartbeat? We needed a level of vibration that would be invisible to the human eye, with no perceptible movement. The only way you would feel the pulse of that heartbeat is when you rest your hand on the cot.

We played with all kinds of ideas; rotating weights, magnets and even clockwork mechanisms. We played with all kinds of improvised contraptions together in our search. Nothing worked well enough. We couldn’t find a silent solution – they all involved friction between moving parts. We were stuck.

Sometimes growing up building and making stuff helps. You develop a kind of mechanical intuition that helps you to overcome functional fixedness and look beyond the obvious usage of a thing. Or so we say – others might say dumb luck – but we’ll take it. It was a moment like this when we stumbled upon the idea of salvaging a solenoid from a door lock. We used that as an energy source, and combined it with a simple spring to distribute the pulse. No moving parts, low power, totally silent. Could it work?

Several weary but hopeful parents volunteered to test out our idea. We held our breath. We turned it on. It worked! The babies settled quickly. Eureka! That was quite an emotional moment for us all, and it gave us the confidence to move forward.

The devil is in the detail

We had a core technology solution. We hadn’t yet included the human element, so we didn’t yet have a product. We needed something that was easy to use, that looked right in a child’s bedroom, and that made sense in the context of the overall experience of trying to get a baby to sleep. We needed to design the technology to be right for people.

We started looking at features and aesthetics. Parents who volunteered for the trial were a valuable source of ideas and contributed enthusiastically. They wanted the ability to peek in the room without disrupting the baby. They wanted to be able to set the product, let it run and not have to monitor it – they figured they’d hear about it if it hadn’t worked. So we designed features like remote controls, night lights and timers into the experience.

To really nail the idea of a mother’s heartbeat, we focussed in on the specific rhythms required. It turns out the ideal range is between 60 and 90hz, which roughly corresponds with the vibration of being in a womb, of feeling your mother’s heart beat, of being in car, and of being in a boat. So they became our settings – womb, heartbeat, car, boat.

Looking for an aesthetic solution proved more difficult. This product was not driven by technology, but by the idea of giving parents back peace and control of their lives. The product had to be sympathetic with a child’s room but at the same time it could not be a toy or other children would find it too intriguing.  Eventually we settled on using an elephant’s foot motif. The reference was well received by the parent group, because it had a strong emotional association with family, protection and also physical robustness. Importantly the motif also was gender neutral.

The product, now christened the ‘Lullabub’, had four modes of operation. Mother’s womb, Heartbeat, Car and Boat on the water.

Magically rocked back to sleep?

Chris was very excited about the huge potential of the business we’d helped him build. The initial run of 5000 products all sold out in the first 2 years. Pretty good for a side business.

But Chris would agree we were more excited about the human impact we had together. Since the real end-users we were all designing for are a little young to speak for themselves, we’ve had to satisfy ourselves with their spokespeople; the hoards of delighted, well-rested parents. When Chris when he started receiving emails like this from parents, we knew we’d done something great together.

By ||Comments Off

Rover

The Challenger

Lawn Mower

A sunny weekend, the radio on, a beer nearby and the grass a little longer than you’d like. Rover has been quietly enabling this iconic Australian experience for over 50 years. But in 2008 when we were invited to start a conversation with them, times were rapidly changing around them and they needed to evolve to keep up.

Like many great Australian manufacturers, Rover was being challenged by changing market conditions. Their margins were being eroded by low cost Asian competitors, and high-end European and American competitors were threatening to take away precious real estate in key retail channels. They were being squeezed from both sides, and the high Australian dollar wasn’t helping.

Read More

They had responded quickly to reduce cost and gain efficiency by moving some aspects of their own supply chain to Asia. With that well underway, Rover were looking to put those hard-earned efficiency gains to work by building a substantially stronger value proposition – an innovative new hero product to reinvigorate an ageing product range.

The Challenge

Combine Rover’s 50 years of proud Australian mower development experience with CMD’s best practice customer insight, design and engineering skills to create a truly market-leading product experience to match and exceed the best in the world. Together, we set out to reinvent an iconic Australian business by designing a next generation mowing experience to take the fight back to the international market.

Rover called it The Challenger.

The Journey

As with any good design process, we started not with the product, but by trying to understand the experience of the people using the product. To move from competing on cost to competing on value for our customers, we really needed to start with the needs and desires of those customers. Although Rover had over 50 years of experience in mowers, together we really wanted to rethink the mowing experience from the grass up. So we put aside our preconceptions and approached our user observation and research as completely naive, first-time users.

Have you ever really watched people mow? It’s fascinating. When you put aside your own experience, look at it through a naive lens you start to challenge a lot of preconceptions and conventions of what the mowing experience should or shouldn’t be. After a phase of observational research the team discussed the issues associated with professional contractors needing to mow wet or damp grass.

We had witnessed how difficult it was to empty damp clumping grass from the existing catchers on the market. Rover’s research had shown that people wanted larger catchers and our intention was to deliver the largest capacity catcher to the market. However after observing this contractors difficulty in emptying wet grass we knew we had to do better. So we grabbed one of our catchers, cut it in half, put a hinge on it and reviewed it with collaborative R&D group. What if you could just press a button and your catcher would split in half? How much easier would it be to empty?

That simple insight became the patented Croc Jaw. You can’t buy the kind of gratitude that one feature gets from mowing contractors. With these insights and others, we were excited. We’d seen the best in the world and we knew we could do better.

At the same time as this people-centred research, we were meticulously reverse engineering all of the leading mowers in the market. It was a bit like reading the rings in a tree we could see every detail, every decision that went into their development. Where they compromised for cost, where they over engineered for quality, where they messed up and had to fix it after the fact. Armed with that knowledge and with the strength of our network of supply partners we were able to create benchmark costs that matched or bettered the competition.

How might we curate a family of breakthrough mowers tailored to different user groups, not just one model forced upon everyone? Armed with our benchmark costs, we set after this challenge. An average car probably comes in three or four different models. In the end the Challenger had around seven models, from the cheaper model for mum and dad right up to the top of the range professional mowing contractor solution. It was quite a challenge. It wasn’t enough to design the different models so they made sense in terms of price point, functionally and value proposition. We also had to get clever in designing modular components that could be reused throughout the range, reducing tooling costs.

All that thinking would be useless if the mowers didn’t visually communicate their value instantly to people in stores. It takes just a glance for people to make judgements on how much they believe something is worth. So we spent a lot of time with customers understanding how they understand mowers visually. We found that people understand mowers by referencing cars and power tools (“That’s definitely the better mower, it has mag wheels like a sports car”). So we designed those aesthetic references across the product range.

As we moved into preproduction, we set about helping Rover adopt a number of new prototyping methods. It had been many years since they’d done ground-up new product development and technology had moved on. Using our knowledge of best practice engineering methods, we were able to achieve a number of technical innovations such as the use of incremental sheet forming to create a functioning and mechanically precise mowing deck prototype. This allowed us to accurately assess mowing performance, noise and vibration months in advance of receiving production ready press tool samples. Our advanced network partners from the Automotive pressing industry also helped us develop the deck design and tooling so that it could be successfully pressed full shape in a single phase. Something that Rover had not achieved in many generations of product. This allowed us to achieve a much higher quality finish, and reduce tooling costs considerably.

The Impact

When it hit the market, the Challenger outperformed all other comparable products on the market.

Amongst a long list of new features we believe the Challenger boasts:

  • the largest catcher capacity
  • highest cutting performance (vortex and flow rates)
  • largest wheels (to reduce rolling resistance)
  • the only mower able to cut right to the edge of the grass on both sides of the mower (to reduce turning and twisting)
  • electric start options instead of the old “rip cord” starter
  • the back saving “Croc Jaw” catcher mechanism which splits the catcher on a hinge to allow you to easily empty the high capacity catcher; and
  • greatly improved ergonomic handles and general maneuverability (to minimise strain through frequent use)

 

 

By ||Comments Off

GroundProbe

Work Area Monitor (WAM™)

CASE FOR CHANGE

Workplace safety in a modern mine.

The open cut mining industry is quite literally huge. Safety is a critical aspect of this kind of mining and the biggest issue is slope stability.
It presents a very real and present danger to workers and machinery.

Should a rock fall or slide happen, there can be an evacuation and shutdown of the mine for long periods of time. Shutdown costs spiral very quickly.

Read More

Historically, surveyors are brought in to establish if the area is stable. The process is time consuming and costly. Often the outcomes of the surveys are not conclusive, leading to high risks for workers and further delays in operation.

Enter GroundProbe and the WAM™ (Work Area Monitor). The WAM™ uses a proprietary radar technology to monitor slope stability in real-time. In layman’s terms the radar scans the slope of a mine looking for wall movements that foretell an imminent slope collapse event.

Partnership

CMD was invited to partner with GroundProbe to bring the WAM™ technology to a commercial platform, both in terms of its human useability and its technical implementation. This involved customer and stakeholder engagements leading to critical insights and discoveries that drove the technical development.

Discovery Notes

There were many discoveries of note however the critical issues were reliability, portability, deployment time, automatic communication and simplicity of operation (one person deployment).

Project Highlights

The WAM™ project was an absolute pleasure to work on. There were moments of frustration, and moments of triumph. Here are a few of the good ones:

  • Watching serious engineers become children again while building and playing with full size foam core models of proposed deployment platforms.
  • Working right through the night to assemble the first fully working prototype for a GroundProbe board meeting 9.00am the next day.
  • Driving the prototype directly into boardroom at 9.00am the next day, parking, deploying and demonstrating the fully working system (all in less than 3 minutes).
  • Having the development partner mine site lock the gates as we tried to leave with the prototype after two months of testing. They wanted to buy it and wouldn’t let us leave unless GroundProbe agreed to sell it to them…

Outcomes

In field results have been impressive. The WAM™ has successfully predicted and managed dozens of collapse events. Not one worker has been hurt or an asset lost during a WAM™ watch.

Built onto a mine vehicle to allow easy driving access to work areas, the WAM™ is quick to set up and easy to use.  When wall movement is detected, the WAM™ transmits visual alarms and audicble warnings to each crew member via their Personal Alerting (PAL) devices.

Information gathered by the system is displayed in 3D. Colour coded images quickly inform operators of local levels stability within the area being monitored (green good, red bad).

The need for human monitoring is bypassed in critical situations, any imminent danger is reported, and alarm beacons automatically activate in a key locations.

Following a collapse event the WAM™ establishes quickly whether the affected area is now stable.

Future

The future vision of the system is one of complete mine safety integration. Individual workers and assets within the protected area will be tracked and coordinated from a central location. The WAM™ system will be part of an intelligent fully automated real-time network of predictive safety monitoring.

By ||Comments Off

Cook Medical

Endovascular Graft Delivery

Artery Stent Graft Deployment

Often you just want a product to do its job and get out of the way. When a surgeon is operating on your damaged arteries, they have enough to think about. You want them focused on operating on you – not how to operate their tools.

When we started a conversation with Cook Medical, one of the world’s leading medical device companies, we both really wanted to respect that truth. A great surgery in progress is a sight to behold; every movement carefully considered, graceful, precise. In that context, the best medical product should almost be an invisible aid. It should only be there just as much as it needs to be, no more.

Read More

When together we started work on a new endovascular graft device to support damaged arteries, our questions started there. How could we embed the wisdom of great surgeons? What if it felt so safe the right result became almost inevitable? How could we design a device so intuitive it felt effortless? What if using it felt like being guided by hidden hands?

The Challenge

Cook asked us to help them explore the future of endovascular graft delivery devices – precision tools used to deploy stent grafts into a patient’s artery to reinforce narrowed or weakened artery walls.

Embody that research and intellectual property in the medical equivalent of a concept car – an innovative, working and production-ready prototype that fulfills the complex human and technical needs of a highly demanding surgical environment.

The Journey

Surgery to deliver an endovascular graft demands a product solution that reduces the chance of human error and provides the surgeon with great precision, control and above all, a very high level of confidence and safety. In this environment, failures can be fatal. Having a rigorous understanding of the human factors was critical. So with the help of Cook’s R&D team, that’s where our discovery process began.

How do you design a great surgery product when the surgeon never even looks at it while its in use? One of the big insights was that surgeons aren’t actually looking at the person they’re operating on during these procedures. Because endovascular procedures are done through keyhole surgery, there’s not much point looking at the patient unless you’ve got x-ray vision to see inside them. So the surgeon’s eyes are glued to an overhead monitor showing a live x-ray. Looking at the product is a dangerous distraction from taking care of the patient.

With their eyes occupied, this kind of surgery is done by touch and by sound. So we designed the device to be operated “blind”. There’s a very particular order in which the surgery has to happen – insert, move smoothly to the target area in the artery, stop, deploy the scaffolding graft, retract steadily. The surgeon needs to be able to find the each corresponding area of the product by touch, and then measure their progress by vibration and by sound. All through the thick, heavy surgical gloves which a surgeon is always wearing.

In response to this, we designed the rhythmic click of the retracting ratchet to tell the surgeon they’re progressing steadily, a sharper click to tell them they’re done. The tactile feeling of the distinct shapes and textures on different parts of the device lets them know exactly where they are and where they should be, and the device simply refuses to work if the surgeon starts using the wrong area. The delicately balanced weight of the device is light enough to let them feel the movement of the wire through the artery, but heavy enough to resist any potential twitch movements.

While the human interface issues were incredibly challenging, the technical requirements of making it manufacturable were equally challenging. It was no mean feat to balance the the technical needs of sophisticated mechanisms in very small spaces against the often conflicting human needs we were hoping to address – all in a strictly regulated environment.

Our intensive concept phase required a balance of technical and creative problem solving. We iterated through multiple ideas, pulling apart and prototyping, testing, discarding, all in the hopes that we were failing forward towards the right solution. Arriving at the final working solution was all the sweeter when we were told multiple outside engineering teams weren’t able to do what we had done together with Cook.

The Outcome

The resulting design has been awarded several international patents and has continued to inform Cook Medical’s product and IP development, underscoring their competitiveness for years to come.

With significant competing technical, operational and safety demands, Cook’s endovascular graft delivery device proved to be one of CMD’s most ergonomically and mechanical challenging designs, and ultimately one of our most satisfying endeavours.

By ||Comments Off

BlueAnt

Z9

Bluetooth Headset

BlueAnt was struggling. They were competing on cost in a crowded headset market dominated by ‘me too’ products whose life cycle was typically measured in months. Their traditional business based on selling re-badged Asian products was no longer competitive.

They had secured proprietary rights to a noise cancelling technology which would give their headsets a significant technical advantage, but knew that great technology on its own is not enough. They needed a partner to help them fully exploit this technology by designing it into a product to really excite people.

Read More

THE CHALLENGE

Change the game for BlueAnt. Help them escape the cycle of short-lived, low cost products. Design a premium product experience that offers enduring value to BlueAnt’s customers, and by doing so, enable BlueAnt to make the shift from competing on cost and technology with OEM sourced and re-badged product to providing customers value from their own innovative and proprietary product range.

The Journey

By working closely with BlueAnt, our discovery process moved ahead quickly along two lines – human and technical. We pulled apart over 150 competing headsets and analysed them in terms of features, engineering, cost of goods, market positioning and overall value. But we didn’t just want to come up with a product based on our own assumptions. We wanted to know the needs of the real people who would use and interact with BlueAnt. So we also spent a lot of time engaging with BlueAnt’s customers and other stakeholders.

The results were clear. People felt headsets were a corporate product, not a consumer product. This was backed up by our own review of the products in the market. Women especially felt incredibly alienated by the headset designs of the time, which were very masculine. Judging from their appearance, you’d be forgiven for thinking the primary target demographic for headsets were American hip hop artists, not (male!) corporate power-brokers. Gangster bling was in.

They also weren’t very adaptable to changing needs and trends. These products were on-trend, but they quickly became dated and irrelevant – hence their short life cycle.

We saw a significant opportunity for a consumer-focused headset that blended classic, clean, timeless styling with a modular and adaptive design that allowed it to incrementally change over time. It would have broad appeal, and would be inclusive to women. If we could do it right, BlueAnt would be able to attract a broad market segment and deliver compelling product that would be relevant not for a few months, but for years. Real quality lasts.

Achieving this would not be a simple task. The noise cancelling hardware had very specific and very strict technical requirements governing internal volume and harmonics.

Together with BlueAnt’s team, we explored hundreds of concepts in our quest to achieve a product that blended timeless quality, technical excellence and low cost of production. By collaborating closely with manufacturing stakeholders and end-customers, we rigorously tested numerous prototypes for harmonics, technical feasibility and market appeal.

Finally we arrived at a solution that excited us all. The selected concept was small, sleek and sophisticated appealing to both male and female markets. It was aesthetically on game relative to emerging trends in the corporate and lifestyle communication product markets. Stylistically our concept was supported with the release of the Apple iPhone 3 whose form language matched perfectly.

But for us, the work doesn’t stop until the product is in the market. CMD continued to work with BlueAnt throughout the pre-production engineering and launch process, designing distinctive packaging and point of sale materials, and even relocating designers to China to coordinate the pre-production manufacturing and handover.

THE OUTCOME

Together we’d delivered a truly valuable product experience, and BlueAnt’s customers voted with their wallets. The 2007 launch of the Z9 product exceeded even BlueAnt’s wildest expectations, enabling them to establish a dominant market position. In its first year of release the product sold over 2 million units worldwide and won the CES International Design and Engineering Award.

On the back of this success, BlueAnt grew from a $5M company to a $25M company. CMD and BlueAnt continued to develop new products that extended the BlueAnt range. While competing products were struggling to last more than a few months in the market, BlueAnt’s Z9 range still sells competitively and profitably five years later.

 


By ||Comments Off

AI Scientific

Pathfinder 900

Pathology Labratory

The PathFinder is a fully automated system for all pre and post-analytical tasks that are performed within a pathology laboratory. The 900 provides laboratories with Intelligent Patient Sample Management to improve the efficiency and work flow of daily operations.

The unique modular design allows the 900 to be easily installed into any laboratory to perform complex functions ranging from, unloading test tubes, identify and verifying samples, de-capping primary tubes, Aliquot samples, labelling and cap secondary tubes and robotically places tubes directly into sorted racks whilst continually communicating with a central database called Laboratory Information Systems (LIS).

Read More

The PathFinders unique design is a modular system, any modules can be replaced within a 20min period this means easy repairs reducing costly down-time due to repairs. The PathFinder has 4 robotic sorters that process incoming samples, samples tubes are robotically placed in holders (called Pucks). Pucks are RFID enabled which identifies samples in addition to the barcodes present on each tube. The Puck is constantly monitored as it progresses through the PathFinder and tubes are also optically scanned as they pass through the Identification Module ensuring the PathFinder is Error Proof in its monitoring and processing of samples.

The PathFinder was designed primarily for the European market, a highly resolved form was needed. The unit is available in Orange, Yellow, Red & Blue. Colours were chosen specifically to help break down preconceived ideas of how a medical device should look. Great care has been taken to facilitate easy cleaning and sterilisation at the end of each day.

The PathFinder 900 is a full-feature automation system for all pre/post-analytical tasks performed within pathology laboratories. It provides full specimen tracking and preparation within one enclosure. A unique modular design enables the PathFinder 900 to be easily installed within any laboratory to perform the following functions:

  • Unload tubes from racks
  • Identify and verify tubes
  • De-cap and Re-cap primary tubes
  • Aliquot, label and cap secondary tubes
  • Place tubes directly into sorted racks
  • Specimen archival and retrieval
  • Continually communicate with the LIS (Laboratory Information System)

Attention to detail is obvious in every area of the PathFinder. From the robotic modules through to the selection of fasteners, every area has been carefully considered to ensure the device is appropriate, durable, reliable and accurate.

PathFinder has been thoughtfully designed with ergonomic data at the vanguard from the outset. Every aspect of user interaction has been visited, work surface and monitor heights do not disadvantage any users within the anthropometric spectrum. Hip activated retractable shelves, allow operators to access bench space whist carrying a tray loaded with samples.

Assembly and servicing has also been considered with modules designed to be easily lifted and replaced without exceeding ergonomic guidelines for excessive weight.

There is a increasing demand within laboratories and hospitals for equipment that can accurately and rapidly process specimen samples. Quality, attention to detail and product efficiency has ensured the PathFinders longevity in the market. All components used meet or exceed the requirements of the ROHS and Low Voltage Directives. PathFinder has been “designed for disassembly” and boasts a reclaimable/recyclable material content of greater than 95%. Every effort has been made during the design of PathFinder to ensure a reduced negative effect on human health and the environment.

PathFinder can be delivered and assembled by a single technician and be operating the same day.  This feat is remarkable given the complex nature of the design. All parts of the PathFinder have been designed to fit into the dimensions of some of the smallest lifts in Europe.

By ||Comments Off