Production Management & Prototyping
I have had the pleasure of working with industry leading brands to develop new product, innovative designs and marketing promotional material. Most of the work undertaken requires Research & Development for proof of concept, utilising local and offshore rapid prototyping for sample approval. Working to strict, tight deadlines.
I have put together a small collection of projects that either were one-off custom units or large assemblies with complex production elements.
During my time as Popcorn Displays I quickly got comfortable working with the various machines and practices out in the factory. The Facility was setup as a customer/stock storage, prototyping and assembly space. Most of the machines were used for prototyping or small production runs, with myself as the technician for programming, upkeep and routine safety. I quickly took the space as my responsibility as 90% of the work undertaken was for the client I managed. I took charge of hiring/rostering as well as production scheduling on top of my growing list of clients.
Before departing I had increased efficiency in the space and a solid body of reliable, detail oriented casual staff. Over the last 24 months (during Covid) we have 3-5 staff on with social distancing and covid safe practices in place working on up to 3 projects at a time. The busiest Popcorns been in years.
As the Client Manager for Dulux Group I was approached by the Cabots Woodcare Team to develop a new way to display their Sample Boards. Their brief was very straight forward and unrestrictive. Currently the expensive to make/upkeep boards are displayed at the end of an aisle - often two aisles away from the woodcare product. The cluttered, 2m tall wall of wood samples makes for an eyesore and headache to find what you’re looking for. The client informed me that they often have 4-6 facings of the same product and space on shelf could easily be utilised if necessary. Woodcare were losing sales from customers wondering the aisle not knowing that product was needed for their home projects. Shopping becomes too hard and they leave unsatisfied, basket empty. The team needed to draw traffic into the aisle, have silent shopper style education and add buyer confidence, something sorely lacking in the department.
I developed an in shelf panel made from this sheet steel that could hold the existing panels, savings cost. The unit came in two sizes depending on the Can Size required on-shelf and displayed the relevant samples to the product it adjacent to it. This way the information the customer needs is right in front of the product they need. The small unit has optional video screen which plays application and how to videos related to the product - updated via SD card by Reps. The large display can take up to 6 sample boards with help of the very interactive and enjoyable spinner panel. Or alternatively be dressed up with interchangeable graphics to educated the shopper on promotions, application or trips & tricks. The displays are only 200mm max. depth so extra stock can be stored behind. Because the unit is so light and compact it fixes using magnets and a rubber foot and can be installed by Brand Reps. The sample shown here was a hit and is currently being shown to all the independent retailer teams to secure buying power and go to the next stages.
ShaverShop approached Gillette to create a shopper education/category management tool for their range. Gillette has over 9 styles of shavers available at most retailers and many customers don’t know the differences.
The Bay draws customers in with colour blocking and then displays the various Gillette product, benefits and features.
This prototype was installed inShaverShop Chadstone Shopping Centre, Melbourne. It managed to stabilise the decline in sales - Gillette and ShaverShop are now discussing the next step to develop a greater solution to boost sales and implement store-wide.
Sonos contacted us directly to help them develop a new Home Theatre Bundle. The Bundle consisted of 3 pre-existing products available online but not yet sold as a discount set instore. Usually Global Brands such as Sonos would have their packaging designed and made inhouse by their Santa Barbara, CA USA product team. Due to the limited run/trial of the bundle in Australia we were given the task of developing the outer packaging.
It was important to get the Sonos signature unboxing experience right. Quality and above all support and strength were integral to keep the premium, fragile product inside safe. We had 3 rounds of production samples made inhouse and sent to the Santa Barbara product team for review before given the green light to proceed.
The units are currently being sold in select stores (2020-2021) and if successful will be preproduced and distributed across APAC.
Lavazza approached us to create a podium display for their Capsule-Machines in Costco. Simple request but with an incredibly tight budget and small batch run of only 10-15 units a year. The unit has to sit 30mm of the ground, support some heavy machines. Enable the units to be discreetly plugged into power with a branded lip and header, and updatable sleeved for product info.
I engineered the unit to be extremely lightweight and durable - low cost and fast to manufacture. The base is made from gloss white folded Aluminum Composite Panel, bolted to an MDF skeleton with furniture fittings and slotting cross members to support the product weight. The front lip, header and logo are all reverse UV printed clear Acrylic to match Lavazza’s signature blue. The header has relief holes for power cables, then finger screws into the Aluminum Panel with the help of sheet nutserts (inset nuts).
An example of what looks simple and cost effective but took up to 5 different machine processes and light engineering to accomplish. This batch production project has run 3 times as the brand expands to new retailers and wants to make their mark in store.