CASE STUDIES

Product Redesign

John Deere Construction and Forestry Division

Project Scope:

In 2003 the John Deere small four-wheel drive loaders were completely redesigned to improve performance, styling, and cost while complying with Environmental Protection Agency Tier 2 emissions requirements. With full time on-site project management support and expertise in cosmetically sensitive sheet metal components, Morton Metalcraft Co. was selected as the primary tank and sheetmetal supplier for this project. This consisted of 100 top level parts made up of over 300 lower level components, with complexity ranging from simple brackets to cosmetically sensitive hoods, doors, and hydraulic reservoirs.

Project Highlights:

Morton Metalcraft Co. was involved from the very beginning. Our on-site Engineering Project Manager participated in a best-in-class study to understand competitor’s machines and establish design benchmarks and project goals. The team was involved in developing design concepts, establishing cost targets, and cost reduction activities to keep the project on track. We produced engineering samples for stress tests, prototype builds and production startup. Some of the resources utilized to ensure a successful program launch were:

• Weekly team meetings with customer supply management, quality, and design representatives.
• Pro-Engineer software to share engineering information for quality planning, tooling and part production.
• Weekly APQP (Advanced Product Quality Planning) meetings were conducted with Morton Metalcraft Co. engineering, purchasing, quality, manufacturing, tooling and prototype departments.
• Morton Metalcraft Co. engineering representatives provided on site support during prototype and production builds.

Results:

• Produced all tooling and prototype parts from prototype drawings on schedule.
• Met or exceeded delivery, quality and cost objectives.
• Since this project MMC has been selected as the primary tank and sheetmetal supplier for upcoming four- wheel drive loader products.