How improvements in one area sometimes lead to innovation in others

The brief

Belron® is the world’s largest vehicle glass repair and replacement company. But despite their success, they had been noticing a problem - windscreens were getting harder to remove. The adhesives used in recent years have simply got better, meaning considerable physical strength was required to cut it out, which in turn was greatly increasing the chance of damage to the vehicle (not to mention the technicians). The challenge was to develop an improved tool that would reduce effort, minimise damage and improve control. 

What we did

Our team of behavioural researchers, designers, ergonomists and engineers completed extensive field research throughout Europe. Over a series of months we worked closely with Belron to understand all windscreen removal scenarios fully, and to test current methods and tools. Our initial ideas were then tested and validated in our laboratory before a single route was hit upon. We quickly embarked upon a rapid iterative process of 3D CAD development, prototyping and field-testing throughout Europe, which was soon approved. We then managed all tool development, assembly and oversaw final production in the Far East. 

Result

We helped Belron reduce the physical effort required by technicians, speed up the removal process and reduce the potential for vehicle damage, all in one tool. As a result, they now call us their ‘first port of call for any problem’.  

Client's Comments

"PDD fully understands the nature of our business. It has identified a number of innovative opportunities, from natural technical evolvement to truly blue-sky ideas that will revolutionise future business. PDD is our first port of call for any problem."

Chris Davies, Head of Technical Research & Innovation