1 Client: Pallet Display Systems

2 Product Description The product is a tubular metal support system that, in its simplest form, allows conventional wooden pallets to form tables, benches or display shelves for garden centres and DIY outlets. At the other end of the scale they allow footbridges to be built by organisations that require temporary elevated footpaths through flooded areas or by the military to provide light bridges capable of taking Land Rovers.

3 Critical Issue
Manufacturing cost was too high. Because of welded joints, pre-coated tube could not be used. The tube had therefore to be sent out for powder coating after welding which also added additional cost due to difficulties in storage, handling and transportation. Final despatch was also expensive because the stands would not nest for efficient transportation.

4 What we did
Following the initial discovery meeting to understand the issues, we held some concept generation workshops to identify ways of eliminating the welding and the costs associated with the powder coating process. This identified both potential proprietary and bespoke solutions. Options were assessed and a solution chosen similar to the mechanical configuration used for bicycle handlebar stems. This was costed, sources of supply identified and mechanical testing for proof of concept carried out.

5 Outcome The new concept proved successful, enabling pre-coated tubes to be used and allowing the legs to be transported in the disassembled state. The manufacturing cost has been reduced by 43% and the company has recently announced a significant order for the new product. 6 More information Contact Don Rickard at Innovation-Direct on 024 76 572 505 November 2002