Development of a Web-Based Configurator for Automated Fall Protection System Design

The client’s sales team collaborates directly with distributors and installers to create custom fall protection system designs. The process relies on a draftsperson skilled in CAD software, leading to lengthy quote generation cycles exceeding 4 hours. Post-presentation modifications often require manual updates or markup of printed designs, resulting in unprofessional visuals and inefficient resource utilization. Additionally, engineering and design teams are underutilized for complex or non-standard configurations. The lack of an automated, visual, and integrated system hampers sales efficiency, delays manufacturing, and affects overall business agility.

A mid-sized manufacturer specializing in custom industrial safety and access solutions aiming to streamline design, quoting, and manufacturing workflows through an integrated digital platform.

• Reduce quote preparation time from over 4 hours to approximately 30 minutes, enhancing sales throughput.
• Increase quoting consistency and accuracy by automating parts listing and engineering constraint application.
• Enable sales teams to generate professional, detailed design outputs suitable for client presentation and manufacturing integration.
• Allow direct transition from design to manufacturing by integrating the configurator with ERP systems, reducing lead times and errors.
• Support ongoing system upgrades, including new configuration modules (e.g., roof mapping, ladder configuration), to accommodate growth and diversification.

• Automated workflow that replaces manual paper-based design processes.
• Browser-based 2D and 3D visualization to allow users to see complete system designs interactively.
• Generation of professional PDF deliverables suitable for client proposals and manufacturing documentation.
• Real-time parts list creation compatible with ERP systems for quick quoting and manufacturing planning.
• Support for importing and utilizing existing 3D parts models within the configurator.
• Features to support complex system components such as brackets and braces with specific attachment angles.
• Additional modules including roof system mapping, ladder configuration, and fall protection type selection.
• Administrative controls for user access, permission management, pricing adjustments, and system customization.

• ERP systems for parts data import, pricing updates, and order automation.
• 3D CAD/model repositories for importing complex component models.
• Building plans or site drawings for roof mapping features.
• Authentication and user management platforms for centralized admin controls.

• Scalability to support growing user base and additional modules without performance degradation.
• High-performance 3D rendering optimized for browser environments.
• Robust security measures for user authentication, access management, and data protection.
• System availability and uptime reliability suitable for enterprise use.
• Maintainability and extensibility of the platform for continuous improvements.

The implementation of the web-based configurator is expected to drastically reduce quote preparation times from over 4 hours to approximately 30 minutes, improving sales efficiency and customer experience. Automated parts listing and engineering rule application will enhance quoting accuracy and consistency, minimizing errors. Direct integration with manufacturing systems will shorten lead times, reducing production cycle by up to 34 days. Overall, these improvements aim to deliver at least 80% return on investment internally, facilitating scalable growth and enhanced partner collaboration.