CASE STUDY · COMMERCIAL
Metal Lockers for Thinventory (ByBox)
JC Metalworks recreated Thinventory’s existing locker design from physical samples and standardised components to support consistent, repeat production.
- Security Details: Sealed rivets, security screws
- Component Standardisation: Simplified repeat fabrication
- Design Adjustments: Improved sheet material use
- Storage and Despatch: Inventory support before despatch
INDUSTRY
Inventory Management
PRODUCTS
Metal Inventory Lockers
SERVICES
Reverse Engineering & Fabrication
OUTCOME
8,000+ Lockers Delivered
Background
Recreating a Locker Design for Repeat Production
Thinventory, previously known as ByBox, provides inventory management solutions for field service companies. Its inventory lockers help customers maintain visibility and control of stock in real time.
For this project, JC Metalworks was asked to reproduce Thinventory locker designs at volume. The customer supplied sample lockers, but engineering drawings were not available to define the complete construction. The team therefore needed to establish the dimensions, materials and build details from the physical samples before moving into repeat production.
The work combined sample-led reverse engineering with practical adjustments to component design and standardisation. Storage support was also part of the original project arrangement, helping manage locker inventory ahead of despatch.
Challenge
Reproduce Existing Lockers Without Engineering Drawings
The sample lockers showed the intended product, but the project did not come with engineering drawings. JC Metalworks needed to understand how the lockers were assembled, work out the dimensions of the individual parts and identify the materials and fixing details used in the original construction.
The volume of lockers required and the need to respond to demanding delivery timelines made an efficient, repeatable production approach important. The team had to translate the samples into practical fabrication information without losing the construction details needed for the finished locker.
Engineering From Physical Samples
Establish overall dimensions and component details, including shelves, hinges and locks.
Material and Construction Assessment
Identify the steel types used across the locker body, doors and internal components.
Security-Related Details
Understand the fixing approach, including sealed external rivets and security screws in place of external screws.
Production Repeatability
Standardise components where possible and make minor design adjustments to support fabrication and sheet-material utilisation.
Solution
From Customer Samples to a Standardised Production Route
JC Metalworks examined the supplied lockers to understand their material composition, geometry, fabrication methods and assembly. That information was used to establish a practical route for reproducing the metalwork, with component standardisation and selected design adjustments supporting more efficient repeat production.
01 · REVERSE ENGINEERING AND MATERIAL ASSESSMENT
Establishing the Locker Construction
With no engineering drawings available, the team carried out a detailed review of the customer-supplied samples. Measurements were taken across the complete locker and its individual parts, including shelves, hinges and locks, to understand how the components related to one another and how the units were put together.
The assessment also considered the materials used for the locker body, doors and internal components. Galvanised steel and Zintec were the primary materials used for the lockers. JC Metalworks used these materials to recreate the existing locker design in fabricated sheet metal.
02 · SECURITY-FOCUSED CONSTRUCTION DETAILS
Security-Focused Fixings
The lockers incorporated stainless steel or steel fixings, sealed external rivets and security screws in place of standard external screws to help deter tampering. These features were retained in the fabricated design, keeping the lockers aligned with the original sample while addressing practical security requirements.
03 · REPEAT PRODUCTION AND DESPATCH SUPPORT
Standardising Components and Supporting Delivery
JC Metalworks standardised components where possible, making minor design adjustments to suit the fabrication process and make more efficient use of sheet material while retaining the key features of the original locker design. This established a consistent approach to repeat production and provided a basis for future locker designs.
To support Thinventory’s inventory and delivery needs, JC Metalworks also provided storage for completed lockers before despatch. Its central location helped reduce transit times and simplify handling.
RESULTS
A Repeatable Approach to High-Volume Locker Supply
The project brought together reverse engineering, materials assessment, attention to security-related fixings and component standardisation. Instead of relying on drawings that had not been supplied, the team used the customer’s physical samples to establish the locker construction and inform the production approach.
More than 8,000 lockers were delivered, demonstrating JC Metalworks’ ability to translate the existing design into a repeatable production process. Standardised components and consistent construction details helped maintain the design across production runs.
Physical samples guided locker recreation.
Galvanized steel and Zintec construction.
Security fixings helped deter tampering.
Standardisation supported repeat locker production.
Here at Thinventory, we do work with a lot of suppliers, JC Metalworks are by far one of the best that we work with due to their flexibility and constant willingness to go above and beyond.
– Kevin Barrs, Service Product Manager.
METAL LOCKERS FOR THINVENTORY (BYBOX)
A project summary for procurement, engineering and product teams working on locker systems and recurring supply programmes.
Includes project background, sample-led reverse engineering, material and construction details, standardisation for repeat production, and storage support.
