The Royal Life Saving Society UK (RLSS UK) remains dedicated to advancing water safety education and ensuring our training tools are top-notch. We embarked on the journey to design and develop Manikin Max, a light-skin submersible rescue manikin that meets the highest standards for water rescue training and provides a fantastic tool for swimming pool operators when conducting Lifeguard Zone Visibility Tests (LZVTs). Here’s a look at the intricate process behind bringing Manikin Max to life.
The Initial Vision
Our journey began several years ago with the idea of enhancing our rescue manikins with better materials, realistic submersion capabilities, and compliance with the International Lifesaving Federation standard for sport. Initially, the project faced design and manufacturing logistics challenges, with the early production of moulds in 2017. Unfortunately, progress stalled due to changes in personnel and the impact of the pandemic and Brexit. In 2023, we revitalised the project and were lucky enough to find new manufacturing partners, JSC Rotational, a UK-based company, with the aim of bringing Manikin Max to fruition. This was led by Aaron Dhanda, Head of RLSS UK Shop, who explored opportunities to adapt the design to meet the international lifesaving federation criteria and for the manikin to be used in Lifesaving Sport competitions.
Manikin Max during the manufacturing process
Design Adjustments and Compliance Challenges
Through extensive design trials, technical measurements, and CAD comparisons, we worked closely with JSC Rotational to ensure that Manikin Max met specifications, including height, width, and buoyancy requirements. Adjustments were needed to meet international lifesaving standards, which required precision and the flexibility to adapt our designs based on continuous testing and feedback.
CAD comparisons of two Lifesaving Sport Manikins
For example, we discovered that the circumference at the manikin's base needed adjustments to align with standards. Additionally, the design required a rework to incorporate an external weight system, allowing the manikin’s weight to be adjusted for different training environments. Inspired by the German DLRG manikin design, we introduced a removable weight that could be inserted externally, which proved to be a cost-effective and practical solution.
Investment and Production Decisions
Our partnership with JSC Rotational was crucial in navigating this project's financial and technical aspects. We approved multiple mould changes, with a total investment of £9,400, followed by another in December 2023. Our team also explored ways to reduce costs associated with components, like the plugs used for securing the weights, by sourcing options locally and internationally.
After identifying Rashid at Precision Products Enterprises (PPE) in Pakistan as an affordable, economical, and reliable supplier, we reduced plug production costs, allowing us to make a more budget-friendly product. The final production solution enabled us to produce Manikin Max at a sustainable cost without compromising quality or compliance.
Overcoming Logistics and Supply Chain Barriers
Bringing Manikin Max to market was not without its logistical hurdles. Delays in shipments, including a hold-up of weights for manikin max in the Suez Canal and additional VAT and customs costs, complicated the process. However, we worked tirelessly with our suppliers and logistics partners to overcome these issues, ensuring that production continued on schedule.
Launching Manikin Max
On May 20, 2024, RLSS UK proudly launched Manikin Max. With a new packaging design by Kilby Packaging and production secured with JSC Rotational, Manikin Max is now available for water safety professionals, swimming pool operators and lifeguard trainers around the world. The manikin meets the rigorous standards of submersion and durability required for realistic rescue training, making it a valuable addition to RLSS UK’s line of safety products.
The finished Product
Conclusion
The journey of Manikin Max highlights RLSS UK’s commitment to innovation and excellence in lifesaving equipment. Each step has been a testament to our dedication to quality and water safety, from overcoming design challenges to navigating complex logistics. We look forward to seeing Manikin Max make a difference in training and safety environments worldwide, helping prepare the next generation of lifeguards and lifesavers.
Explore Manikin Max and other lifesaving equipment at RLSS UK's online store – RLSS UK Shop.
At the time of writing, we are still awaiting confirmation of accreditation from ILS for the Orange Sport Manikin to be used in Lifesaving Sport Competitions.