Case Study


Throughout our long term relationship with this global leader in construction and mining equipment we designed and project managed the successful delivery of an overhauled modular operator cab, as well as multiple other mechanical and hydraulic systems. The cab itself was a major project milestone for the success of a new product launch as it contained 12 out of 17 USPs and many cost improvements, enabling the new articulated trucks to launch and sell well despite the global economic downturn

Orion Product Development Case Study – CAT Articulated Dump Trucks

We have worked on a number of innovative new product development and cost reduction projects during a long term relationship to develop the next generation of Articulated Dump Trucks for this leading international brand.

Each project involved the full product development cycle from idea generation, concept design, detail design, stress analysis, engineering drawing, prototyping, testing, project management and costing, using 6 Sigma project management techniques. In all cases we worked to International Standards as well as the customer’s own exacting internal standards and codes of practice.  We integrated into the various project teams at increasing levels of responsibility as the projects increased in complexity, eventually coordinating the engineering activities of project teams across the UK, USA and Europe.

Total project value in excess of £1 billion, with sub projects covering many areas of the vehicle including powertrain, hydraulics, electrical, structural and the operator interface and environment.

Several utility patents have been developed as a result of our work. We also helped to develop 12 out of 17 new USPs (unique Selling Points) listed in an recent updated product catalogue.

Kevin came highly recommended to me from my UK colleagues, following the completion of some high quality project work he had produced for another side of the business.

He was subsequently engaged by me in a multi-disciplinary role at senior level, coordinating several multi-national design teams on a complex, high-value New Product Development project. His creativity, experience and engineering ability added significant value to the project and enabled several patents to be pursued. Kevin has an excellent work ethic and takes ownership of any given task. The program was completed ahead of time and to a very high standard.

We wanted to secure Kevin as a permanent employee at our company, and as such would have no hesitation in recommending him

Articulated Dump Trucks, New Product Introduction Manager

Here is a short CAT video showing the features and benefits of the B Series trucks:

Customer Profile

North-East division of a leading global blue chip construction and mining equipment manufacturer.

Company Size:

Product Complexity:
Very High

Product Value:

Production Volumes: