CLIENT
JLG
MISSION
Responding to new worldwide diesel emissions standards (Tier 4), JLG needed to redesign and consolidate their telehandler product lines worldwide. This was a comprehensive development project touching every aspect of the product line, including up to 33 models for three separate brands.
Brownlie Design was asked to spearhead industrial design development activities for this massive project. Our responsibilities included appearance development for three world-class brands (JLG, Caterpillar and Deutz-Fahr), cab and tractor frame design, participation in ergonomic consolidation and refinement, visibility studies, manufacturing materials selections, A-side surface creation for all appearance and ergonomic details, and production design for counterweights and other key parts.
CONCEPT DESIGN
ERGONOMIC STUDIES
PROTOTYPE CONSTRUCTION
3D CAD DEVELOPMENT
CONCEPT DESIGN
Our team began the process by auditing the existing product brand appearances and key design characteristics. Workshops were held with all stakeholders, including marketing, engineering, manufacturing, and service, and key customers. Using the insights and input gained from the groups, Brownlie Design developed concepts, evaluated design directions, and implemented brand differentiation strategies for the future appearance of the JLG, Caterpillar, and Deutz-Fahr brands.
ERGONOMIC STUDIES
While developing the brand appearances, Brownlie Design simultaneously initiated an in-depth ergonomic review. Plywood ergonomic bucks were built, tested, and refined. Features such as seating location, steering position and adjustability, primary and secondary controls placement, display locations, visibility, and ingress/egress considerations were tested using subjects ranging in size between the 5th percentile for women and the 95th for men.
As part of the development of the physical prototypes, Brownlie Design augmented the evaluation by using PTC Creo and 3D CAD ergonomic study models to evaluate sight lines and minimize blind spots.
3D CAD DEVELOPMENT
3D CAD surface models of all interior and exterior appearance/ergonomic panels were created in conjunction with the engineering development of the designs. This was a cross-functional, multinational endeavor involving development teams in the United States, United Kingdom, Italy, and Belgium. Weekly conference calls were held throughout the process to ensure a cohesive, highly functional design was completed on time and within budget.
APPEARANCE MODELS
To verify the design and allow for its approval, Brownlie Design and their strategic partners constructed a full-scale prototype of the JLG branded cab.
PRODUCTION EVALUATION + SITE VISIT
When production parts were available, Brownlie Design participated in multiple design reviews and fit-up sessions. As a result of the hard work and cohesion among team members there were minimal manufacturing issues. The subsequent success of the design can be seen on construction sites throughout the world, continuing JLG’s reputation as a manufacturer of world-class telehandlers.
