Streamlining innovation: Faster routes to market for global manufacturing

Summary:

Partner: Terex
Sector: Manufacturing (Materials processing and recycling equipment)
Challenges: Balancing high-quality safety frameworks with the need for agility and speed to market in a complex, multi-departmental environment.
Solution: The Verification, Validation and Testing (VVT) tool, developed by The Open University (OU) Business School.
Outcome: Improved cross-functional collaboration, elimination of testing redundancies, and a sharpened focus on the end-customer’s requirements.

The Open University has developed a new online product development tool designed to help manufacturers transform how they verify, validate, and test new products. By providing a structured, high-level view of complex projects, the tool enables clearer decision-making and more efficient testing processes, supporting faster routes to market while keeping customer needs firmly in focus.

Developed by Dr. Khadija Tahera, a specialist in Operations and Supply Chain Management at the OU, the tool was recently put to the test by Terex, a global leader in materials processing machinery.

Background: Bridging the gap between design and delivery

The VVT tool was created to support organizations of all sizes in navigating the rigorous requirements of product development. At Terex’s Northern Ireland operation—which specializes in heavy-duty crushing and screening technology—the goal was to see how this academic innovation could complement their existing, robust safety frameworks.

In big organisations, projects pass through many departments, and the original customer goal can get lost. Your tool can be used to keep everyone aligned and focused on the customer, not just their own priorities.
Ciaran Fanning,
Engineering Director at Terex Northern Ireland

The challenge of agility

Large organisations often excel at delivering high-quality, reliable products, but internal complexity can slow them down. Ciaran Fanning noted that the sheer number of functions involved in a project can sometimes lead to a loss of momentum.

The VVT tool addresses this by:

Breaking projects down into clear, ranked elements.
Identifying which testing activities add real value.
Pinpointing areas of waste or duplication within the testing process.

Efficiency through clarity and collaboration

One of the primary benefits identified during the Terex pilot was the creation of a "shared language." By providing a common framework, the tool encourages meaningful cross-functional discussions. This ensures that from the initial design phase to final delivery, every department remains focused on the customer’s specific needs rather than just departmental silos.

The result is a more streamlined path from concept to completion, saving significant time and manpower.

A transformative resource for SMEs

While Terex demonstrated the tool's efficacy in a global corporate setting, the trial also highlighted its potential for Small and Medium-sized Enterprises (SMEs). For smaller firms that may lack in-house specialist product safety or testing expertise, the VVT tool offers:

A practical way to identify gaps in development.
A method to reduce regulatory risk.
A structured approach to ensure products meet customer expectations.

Conclusion: Driving the future of manufacturing

The collaboration between The Open University and Terex highlights how academic research can solve real-world industrial challenges. By integrating the VVT tool, manufacturers can maintain their commitment to quality while gaining the agility needed to compete in a fast-paced global market.

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