Sheet-Metal Shroud Redesign – Genie (Terex)
As a design engineering intern at Genie, I led the redesign of a complex sheet-metal shroud assembly for one of the company’s Z boom products. The challenge was to make the cover easier to manufacture, faster to assemble, and more robust in the field—all while cutting cost and eliminating quality headaches.
Genie Z boom line: application for the redesigned shroud (representative image)
Design & Impact
- Combined multiple parts and optimized mounting, eliminating redundant functionality and all welded components.
- Reengineered fastener types and locations for faster, error-proof assembly.
- Introduced a new hinge mechanism after a deep DFM/brainstorming session—improving cover rotation and field reliability.
- Results: 30% fewer parts, 100% deletion of welds, $100/unit cost savings, and $20,000/year in savings.
- The new design was prototyped and approved for production.
Skills: Sheet-metal design, DFM/DFA, enclosure engineering, cost-down, prototyping, cross-team collaboration.