Transforming Wiring for Low and Medium Voltage CC
Transforming Wiring for Low and Medium Voltage CC
Digitizing assembler process to save $4M annually
Digitizing assembler process to save $4M annually
MY ROLE
MY ROLE
User Experience Lead
Interaction Design
Visual Design
User Interviews
Rapid Prototyping
User Experience Lead
Interaction Design
Visual Design
User Interviews
Rapid Prototyping
DELIVERABLES
DELIVERABLES
Component Libraries
User Interviews
High Fidelity Designs
Component Libraries
User Interviews
High Fidelity Designs
TEAM
TEAM
Designers
Developers
CAD Team
Manufacturing Engineer
Product Manager
Designers
Developers
CAD Team
Manufacturing Engineer
Product Manager
YEAR
YEAR
2022 - 2025
2022 - 2025
What was the problem?
Wiring up a cabinet
is expensive.
Wiring is a specialized skill, and even experienced personnel can make mistakes. We identified it as a key factor behind rising costs and quality issues. Not only that but it leads to some gross numbers and errors.
Wiring is a specialized skill, and even experienced personnel can make mistakes. We identified it as a key factor behind rising costs and quality issues. Not only that but it leads to some gross numbers and errors.
60%
60%
MCC labor is wiring
MCC labor is wiring
48%
48%
Production issues are
wiring related
Production issues are
wiring related
4+ weeks
4+ weeks
Training required to
read a schematic
Training required to
read a schematic
#1 reason to quit
#1 reason to quit
Job complexities sited as the main reason to quit. These include training and schematic reading.
Job complexities sited as the main reason to quit. These include training and schematic reading.
The Research
We began by understanding the needs
We began by understanding the needs
During the discovery phase, we focused on two main goals:
- Define the workflow & key tasks of assemblers
- Research on some of the competitor apps in the market right now
During the discovery phase, we focused on two main goals:
- Define the workflow & key tasks of assemblers
- Research on some of the competitor apps in the market right now
To ensure the best results, we developed an early prototype that included the core features of the final app. We then tested it with real users, which gave us valuable insights into their behavior, needs, and expectations when using a new application.
To ensure the best results, we developed an early prototype that included the core features of the final app. We then tested it with real users, which gave us valuable insights into their behavior, needs, and expectations when using a new application.
User Personas
We talked with lots of users with varying experience
We talked with lots of users with varying experience
Our user personas ranged from:
- Assemblers who were very experienced in the field with more than 10-12 years of experience
- Assemblers who were completely new to the system and had no prior experience
Our user personas ranged from:
- Assemblers who were very experienced in the field with more than 10-12 years of experience
- Assemblers who were completely new to the system and had no prior experience
Jessica Guadalupe is a veteran when it comes to doing assembly work. She has been doing this for the past 20 years and is very good at her job so much so that she doesn't even need schematics for the medium assemblies. The app should support her current workflow without deviating too much and introducing new elements that might confuse her.
Jessica Guadalupe is a veteran when it comes to doing assembly work. She has been doing this for the past 20 years and is very good at her job so much so that she doesn't even need schematics for the medium assemblies. The app should support her current workflow without deviating too much and introducing new elements that might confuse her.
"
Introducing new things should not alter my workflow too much. I still want the freedom to work the assemblies as I want to.
Introducing new things should not alter my workflow too much. I still want the freedom to work the assemblies as I want to.
Jessica Guadalupe
Jessica Guadalupe
Age : 50 years
Age : 50 years
Role : Senior Assembler
Role : Senior Assembler
Jessica, along side her own work, sometimes help other assemblers in their work as well. Being one of the senior assemblers people naturally gravitate towards her to get help if they are stuck with their own work. This eventually sometimes cause her to miss some of the assembly targets that she had for the month.
Jessica, along side her own work, sometimes help other assemblers in their work as well. Being one of the senior assemblers people naturally gravitate towards her to get help if they are stuck with their own work. This eventually sometimes cause her to miss some of the assembly targets that she had for the month.
Main Points :
Main Points :
Don't want the application to change her workflow too much that she mastered over 20 years.
Application should be easy to follow and built keeping users with less exposure to tech in mind.
Records of the assemblies she has done.
Miguel is a new assembler who recently joined the workforce. He was given training regarding how to read the schematics and do the proper wiring alongside the whole assembly. The app should make things easier to understand for him so that he can pick it up with minimum training and still do the work.
Miguel is a new assembler who recently joined the workforce. He was given training regarding how to read the schematics and do the proper wiring alongside the whole assembly. The app should make things easier to understand for him so that he can pick it up with minimum training and still do the work.
"
I don't have much experience in assembly work and I want my application to make things simpler for me.
I don't have much experience in assembly work and I want my application to make things simpler for me.
Miguel Carrera
Miguel Carrera
Age : 21 years
Age : 21 years
Role : New Assembler
Role : New Assembler
Miguel has gone through the training of doing both the mechanical and electrical assemblies. While mechanical assembly seemed easier with the drawings and details, electrical assemblies took good amount of time (around 12 weeks) to help him understand how to read the schematics and how to make the connections properly using various tools assemblers have available with them.
Miguel has gone through the training of doing both the mechanical and electrical assemblies. While mechanical assembly seemed easier with the drawings and details, electrical assemblies took good amount of time (around 12 weeks) to help him understand how to read the schematics and how to make the connections properly using various tools assemblers have available with them.
Main Points :
Main Points :
Even after training he still is not clarified on many aspects of assembly process.
Whenever Miguel is stuck, he seeks the assistance of senior assemblers which halts their progress on their assemblies.
The application should be user intuitive, and should make the workflow simpler.
The Design Process
Overview from idea
to concept
Following an agile approach to the design and development. We followed a the simple process going from research all the way to delivering the final outcomes to the devs for implementation.
Following an agile approach to the design and development. We followed a the simple process going from research all the way to delivering the final outcomes to the devs for implementation.
Research
Discovery Phase
User Interviews
Competitive Analysis
Idea Generation
Defining Problem
User Journey
Edge Cases
Solutions
User Flow
Wireframing
Prototyping
Edge Cases Design
Testing
Internal Testing
Usability Testing
Delivery
Figma Files
Design Assets
Solutions QA
Research
Discovery Phase
User Interviews
Competitive Analysis
Idea Generation
Defining Problem
User Journey
Edge Cases
Solutions
User Flow
Wireframing
Prototyping
Edge Cases Design
Testing
Internal Testing
Usability Testing
Delivery
Figma Files
Design Assets
Solutions QA
Design Iteration & Prototyping
Building the application with CAD features and wire tracking
Building the application with CAD features and wire tracking
Building the application with CAD features and wire tracking
We built a user-friendly application with key features like Bluetooth voltmeter integration, downtime reporting, project commenting, and interactive CAD model viewing.
We built a user-friendly application with key features like Bluetooth voltmeter integration, downtime reporting, project commenting, and interactive CAD model viewing.
Before
No paper trail
No paper trail
12 weeks to train
12 weeks to train
Wiring prone to errors
Wiring prone to errors
After
Paper trail availability
Paper trail availability
6-8 weeks to train
6-8 weeks to train
Reduced error rate
Reduced error rate
+65%
Improved retention
-55%
Fewer wiring issues
-15%
Less rework needed
The Solution we Implemented
Digitizing the whole process to improve onboarding, efficiency and retention.
We build the application that could provide clear cut instructions to the users. And additionally, have trackability and traceability built in. The final solution significantly improved technician efficiency, reduced errors, and streamlined the overall workflow.
$4m+
$4m+
Savings so far
Savings so far
-60%
-60%
Faster onboarding
Faster onboarding
+65%
+65%
Improved retention
Improved retention
-55%
-55%
Fewer wiring issues
Fewer wiring issues
-15%
-15%
Less rework needed
Less rework needed
Here's the summary
To summarize everything
Here are few short videos we created which tells about the problem (the why we started), the research and the solution. And in the end explaining the impact we've had so far.
Part 1 : Explaining the problem (1:47)
Part 2 : The Research and Iterations (0:55)
Part 3 : The Reaction, Features and Impact (2:33)
Key Metrics
4M$
4M$
4M$
Saved so far
Saved so far
60%
60%
60%
Faster Onboarding
Faster Onboarding
6 weeks
6 weeks
6 weeks
Training time reduced (from 10 weeks)
Training time reduced
(from 10 weeks)
55%
55%
55%
Reduction in errors
Reduction in errors
Have a project you’re excited about?
Drop me a message.
Have a project you’re excited about?
Drop me a message.
Have a project you’re excited about?
Drop me a message.
Have a project you’re excited about?
Drop me a message.
Let’s team up and make something amazing.
Let’s team up and make something amazing.
Let’s team up and make something amazing.