Case Study | Ruroc Design Team and Department Development
Summary:
Established a milestone process to streamline development and manage risk at each stage, ensuring efficient progress without compromising project integrity.
Led the implementation and training for a new Product Lifecycle Management software, enhancing data storage with revision control, sign-off capabilities, and integrated CAD functionality to optimize project management.
Organised the setup of a prototyping, workshop, and testing facility to support rapid iteration and thorough evaluation of product prototypes.
Engaged with a broad community of motorcycle riders to collect real-world data on product usage, which informed a statistics-based life testing plan that enhanced product durability and informed new product development.
Compiled a comprehensive library of competitor helmet test data, enabling effective benchmarking to elevate product performance standards.
Innovated a repeatable acoustic and aerodynamic testing methodology using a wind tunnel equipped with a manikin head capable of multiple directional adjustments and angle variations to simulate various rider positions.
Developed both static and dynamic thermal test methods to systematically assess and refine the efficacy of helmet cooling systems. Developed a new EPS to improve comfort and head-shape fit as well as introduced cooling channels.
Created a range plan for the company, leveraging competitor commercial data and user reviews to strategically position and differentiate new products in the market.
Supported the manufacturing team with contract manufacturer relations, quality and factory layout and production line optimisation.
These strategic enhancements played a crucial role in the facelift of the Atlas 3 helmet, significantly bolstering the company's reputation which had previously suffered due to online criticism over perceived poor quality and safety concerns voiced by motorcycle influencers. By implementing rigorous development processes and innovative testing methods, the Atlas 3 became the first UK brand helmet to meet the new ECE 22.06 standard, effectively silencing its critics. The redesign of key components not only addressed previous issues but also led to markedly improved reviews, underscoring the helmet's enhanced performance and safety features. This turnaround not only reaffirmed the company’s commitment to quality but also restored trust among consumers and enthusiasts alike.
“One standout example of Ben's capabilities was when I assigned him a challenging task right in his first week: designing the floor layout for a new factory we were setting up in China. Despite never having tackled a project of that nature before, Ben took on the challenge with determination and efficiency. In just a few days, he had the design ready, which played a crucial role in getting our factory up and running smoothly.”
Dan Rees - Founder at Ruroc
Results: Atlas 4 Facelift
Upgraded internal lining with new sound-dampening inserts around the ear area. This enhancement boosts the helmet's acoustic performance by 57%, making it the quietest ATLAS model ever produced.
The ATLAS 4.0 stands out as one of the first motorcycle helmets on the market to comply with the stringent ECE 22.06 standard. But we don't just meet these requirements—we surpass them. Our helmet exceeds all testing benchmarks by at least 20%, offering you unparalleled protection and peace of mind while on the road.
Adjustable vents throughout, now featuring a newly added top vent switch for enhanced airflow customisation.
Ruroc’s Atlas 4
Customer Testimonials
“I can’t fault my new Atlas 4, its everything my Atlas 3 was but so much better, the liner is so much better fit, hugs head perfectly. I recall people moaning about noise levels on the Atlas 3, I wasn’t one of them but i would say the noise levels are even better on the Atlas 4. I ride a sports bike with a lot of noise and its great even for me.” - Pete Lay
When they say the Atlas 4.0 helmet is quiet they really meant it!!! Went for a long ride including highway miles and got home taking off my helmet not even realizing I didn’t have my earplugs in! The included sounded deadening pads in the box work fantastic and I truly commend ruroc on an amazingly made product. - Ian Sampayo
“Just received the atlas 4.0 core with mirror visor and all i can say is they dont mess around. I was so desperate to try it at speeds i went out in the rain and i couldnt be happier with the quality comfort and noise level. Best helmet ever!” - Josh Sharpe