Home Projects Innovation to reduce sharps hazards at Belron

Innovation to reduce sharps hazards at Belron

Project Details


The Challenge

Belron are the world’s leader in vehicle glass repair, replacement and recalibration (VGRRR), operating services in 42 countries across 6 continents globally, delivered by its 30,000 employees.

During a windscreen repair, a razor blade is used by technicians to remove excess resin to leave a high-quality finish for exceptional customer satisfaction. However, the supply of razor blades within a technician’s toolbox was leading to the risk of injuries across the business.

The company has an exceptional culture where safety is #1 priority. Therefore, a challenge was set by Belron’s global operations to make razor blades significantly safer, without compromising the quality of windscreen repairs.

After internal teams had attempted to find viable solutions the challenge, Belron approached innovation partner Ignite Exponential to help them think differently and identify a solution that would keep technicians safe.

The Approach​

The partnership with Belron began by immersing ourselves in the role of a technician. The Ignite Exponential team were trained on Belron’s SOP (standard operating procedure) enabling rapid testing of new processes and theories. A deep understanding of the working environment and employee behaviours was then gained by shadowing technicians on the job.

The approach initially aimed to find an alternative method to the razor blade for windscreen repairs. Analogies from finishing processes in other industries were explored, and methods such as chemical, abrasive and mechanical scraping were systematically tested on the process.

However, when no credible off-the-shelf replacement to the blade could be found, our agile problem-solving approach allowed the programme to pivot. Instead we consider how the razor blade could be redesigned and supplied in a safer form to the technicians. This approach aimed to minimise the hazards the razor blade presented.

Prototypes of a safer razor blade tooling were designed, prototyped and tested with technicians in the business for real-world validation.

Successful innovation often requires many stakeholders to be brought on the journey! Our in-house batch prototyping capabilities allowed 250 new, protected blades to be manufactured and distributed to the global operations teams, giving all the opportunity to see, feel and test the quality and safety of the new tooling firsthand.

When making an operational/tooling change, it is critical to ensure other jobs are not unintentionally impacted through a change.  Jobs where the razor blade was additionally used were identified, and replacement tooling was tested & implemented where appropriate.

The Outcome

This successful multi-phase collaboration resulted in a manufacturing specification for the improved tooling. Belron are planning on introducing a new protected, single-edge razor blade that should significantly reduce the risk of cuts, creating a safer working environment for their technicians.


an image of our technical paper
mmWave Imaging Radar

Camera systems are in widespread use as sensors that provide information about the surrounding environment. But this can struggle with image interpretation in complex scenarios. In contrast, mmWave radar technology offers a more straightforward view of the geometry and motion of objects, making it valuable for applications like autonomous vehicles, where radar aids in mapping surroundings and detecting obstacles. Radar’s ability to provide direct 3D location data and motion detection through Doppler effects is advantageous, though traditionally expensive and bulky. Advances in SiGe device integration are producing more compact and cost-effective radar solutions. Plextek aims to develop mm-wave radar prototypes that balance cost, size, weight, power, and real-time data processing for diverse applications, including autonomous vehicles, human-computer interfaces, transport systems, and building security.

an image of our technical paper
Low Cost Millimeter Wave Radio frequency Sensors

This paper presents a range of novel low-cost millimeter-wave radio-frequency sensors that have been developed using the latest advances in commercially available electronic chip-sets. The recent emergence of low-cost, single chip silicon germanium transceiver modules combined with license exempt usage bands is creating a new area in which sensors can be developed. Three example systems using this technology are discussed, including: gas spectroscopy at stand off distances, non-invasive dielectric material characterization and high performance micro radar.

an image of our technical paper
Metamaterial-Based Ku-Band Flat-Panel High-Grain

This technical paper by Dr. Rabbani and his team presents research on metamaterial-based, high-gain, flat-panel antennas for Ku-band satellite communications. The study focuses on leveraging the unique electromagnetic properties of metamaterials to enhance the performance of flat-panel antenna designs, aiming for compact structures with high gain and efficiency. The research outlines the design methodology involving multi-layer metasurfaces and leaky-wave antennas to achieve a compact antenna system with a realised gain greater than +20 dBi and an operational bandwidth of 200 MHz. Simulations results confirm the antenna's high efficiency and performance within the specified Ku-band frequency range. Significant findings include the antenna's potential for application in low-cost satellite communication systems and its capabilities for THz spectrum operations through design modifications. The paper provides a detailed technical roadmap of the design process, supported by diagrams, simulation results, and references to prior work in the field. This paper contributes to the advancement of antenna technology and metamaterial applications in satellite communications, offering valuable insights for researchers and professionals in telecommunications.

an image of our technical paper
Frequency-Scanning Substrate-Integrated-Waveguide Meanderline Antenna for Radar Applications at 60GHz

This paper describes the design and characterization of a frequency-scanning meanderline antenna for operation at 60 GHz. The design incorporates SIW techniques and slot radiating elements. The amplitude profile across the antenna aperture has been weighted to reduce sidelobe levels, which makes the design attractive for radar applications. Measured performance agrees with simulations, and the achieved beam profile and sidelobe levels are better than previously documented frequency-scanning designs at V and W bands.

an image of our technical paper
A Ku-Band, Low Sidelobe Waveguide Array Employing Radiating T Junctions

The design of a 16-element waveguide array employing radiating T-junctions that operates in the Ku band is described. Amplitude weighting results in low elevation sidelobe levels, while impedance matching provides a satisfactory VSWR, that are both achieved over a wide bandwidth (15.7-17.2 GHz). Simulation and measurement results, that agree very well, are presented. The design forms part of a 16 x 40 element waveguide array that achieves high gain and narrow beamwidths for use in an electronic-scanning radar system.

an image of our technical paper
Sensing Auditory Evoked Potentials with Non-Invasive Electrodes and Low-Cost Headphones

This paper presents a sensor for measuring auditory brainstem responses to help diagnose hearing problems away from specialist clinical settings using non-invasive electrodes and commercially available headphones. The challenge of reliably measuring low level electronic signals in the presence of significant noise is addressed via a precision analog processing circuit which includes a novel impedance measurement approach to verify good electrode contact. Results are presented showing that the new sensor was able to reliably sense auditory brainstem responses using noninvasive electrodes, even at lower stimuli levels.

Contact Plextek

Got a project in mind?

Let’s talk

If you have got a project to discuss, or even just an idea, let's talk