Production System Retrofit Ledge Project
THE DESIGN PROBLEM
A customer specifically requested additional counter space on the automated makeline. The challenge was to retrofit a durable work surface onto the existing refrigerated cabinets without redesigning the underlying architecture.
Key Constraints:
• Structural Load
• Retrofit Compatibility
• Repeatable Install, Installation Jigs
IDEATION
Explored work-surface geometry, edge profiles, structural support concepts, and attachment methods while balancing ergonomics, manufacturability, and integration with the existing cabinet.
RAPID PROTOTYPING
Built full-scale prototypes to evaluate ergonomics, mounting strategy, and interference with the existing makeline before committing to the production design.
PRODUCTION DESIGN
Converted the validated concept into a production-ready sheet-metal assembly, defining the mounting interfaces. and manufacturing details required for repeatable fabrication. Created an installation guide as well.
DESIGN FOR RETROFIT & INSTALLATION
Developed the retrofit installation process and tooling for existing cabinets, including alignment fixtures, mounting hardware, assembly sequencing, and installation documentation.
PRODUCTION-READY RETROFIT
The final design provided a robust, production-ready work surface and was successfully integrated into the existing automated makeline.
