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Enterprise UI
User Experience
IoT Design
+30%
Improved task completion rate, achieved by streamlining process touch-points from 4 -> 1 for Prime persona.
-45%
Reduce in time required for users to perform inventory tasks such as checking, creating orders, communicating requirements.
Introduction
Rolls Royce facility located in Indianapolis manufactures aerospace engines and parts. The facility has an automated SAP system to track their inventory which is crucial to their production cycles. However their Welding department has issues with tracking the non schedulable parts, which can’t be managed with through existing SAP system and hence the term non schedulable. Our team set out to innovate an end-to-end IoT solution aided by a mobile-web platform to streamline this process.
MY ROLE
Research, analysis, conceptualization, information architecture, designing high-fidelity prototypes and evaluation.
TEAM
3 Product Designer
1 Developer
1 Project Manager
3 Stakeholders
SOFTWARE
DURATION
8 weeks
Proof of Concept
We built an advanced prototype using the IoT Argon Kit integrated with ultra sonic sensors, and coded a ruled based algorithm for tracking the bin, shelf capacity and the bin quantity. By doing so we were able to validated balance between technical feasibility and viability of the solution. The following video is a demo to check the bin quantity.
Overview of New Inventory managing & Tracking Experience
ITrack: Mobile app main screens
Research
To identify focus points and develop a feature roadmap, we interviewed the stakeholders and cleared out initial assumptions. Desk Research — We conducted initial desk research to understand the facility’s work. Facility Visit & Interview — We conducted a facility tour and an interview with key management staff. We also conducted an informal competitive analysis of existing software solutions for inventory tracking.
Current manual - visual ways of inventory tracking at the RR dept Toyota manages it inventory
We learned more about them by creating a persona and empathy map. Based on the interview, we sketched out all workflows that are performed by the "AEP Welding Staff” and the vendor.
Overall process of non-scheduled parts management to fulfill PO
Key Findings
Ideation
Based on the above key findings and personas, we crafted a Value Proposition Canvas from each persona’s customer segment to guide our brainstorming process; With our holistic understanding of the product, service and the business, we integrated the features with the product architecture. This allowed users to operate with a clear mental model, while navigating the complex interface.
Value proposition mapped from each customer segment
Goals
With one mission in mind, we defined objectives to set our product aspirations. This grounded the team's decision making, and build a consensus within the stakeholder group.
Design
To get past the analysis phase, we sketched then wire-framed our initial understanding of the feature set. This positioned us to show up with materialized ideas, diverge feedback and converge details on iteration.
Evaluation
These were two of our initial high-fidelity prototypes. We conducted a basic heuristic analysis on these and got feedback from our stakeholders. Some drawbacks of these prototypes were that they: 1. Displayed poor user experience — for example, it was tough for users to reach the top dropdown with their thumb. They would have to use two hands in this scenario. Based on this feedback, we improved the next version of the prototypes.
Solution
The non-scheduled parts are placed in the different bins. The proximity sensors are placed on top of each bin. These help us keep track of whether the bin is present or not, and subsequently help us determine the quantity of the non-scheduled part in that bin -empty, half or full.
Fosters current user pattern of working
The system is fabricated in way that accommodates the nomads such as welders by visually alerting them
Less burden on the managing the bin and more focus on finishing the production orders
Easy to implement and get started with the tracking
Proposed workflow with alerting systems integrated on the shelves
DESIGN GOAL: SIMPLE
USER SCENARIO
Manual-visual checking of inventory at the bin-level was epicentre to managing the stock and finishing the PO. Since it is Kanban system, empty bins needed to be moved to the top most shelf, later stocked at dock to return to the vendor. Bins goes missing on the shelves, welders sometimes carry them to workflow and forget to put it back.
SOLUTION
We introduced a new shelf design assisted with IoT and ultrasonic detectors, these give a live, informative 360° glimpse of the inventory, status of bin-levels and on-self vs missing bins. The Live tracking gives auto updates and can be refreshed if need be.
DESIGN GOAL: SIMPLE
USER SCENARIO
The Dept has been accustomed to use Kanban 2-bin system for their welders and in sync with the Pattonair Ltd (return of the replaced/empty bins to refill). They are relied on this sole system to manage and duly dispatch the week's requirement from Rolls Royce.
SOLUTION
With configuration of digital self to reflect their reality, users can quickly customize to the exact view of the self unit they need. The design accommodates the current signifiers “traffic light” indication to support their mental models.
DESIGN GOAL: Flexible
USER SCENARIO
When the engines and kits order is fulfilled based on the PO, there cases of surplus of non-scheduled parts. To accommodate space for the inventory of the new PO, some of the non-inventory parts are sold to other vendors.
SOLUTION
Based on the production orders upcoming or current cycles, with AI suggestions user can avoid selling.
DESIGN GOAL: Automate
USER SCENARIO
The siloed nature of the workflows and departments, the inventory received goes unnoticed. In turn, the MRPC places an order due to time constraints & unable to reach the dock head for confirmation.
MRPC no or minimal communications with Vendors. Only way MRPC gets to know of order delivery is through email. There are multiple shift manager for the each department.
*MRPC -> Material Requirement Planning Controller
SOLUTION
We redesigned the communication flows by requesting the vendors at each stage of shipment. Within this centralized interface the option to toggle between departments and resend a notification after/during the order delivery process, it enables user to focus on the PO rather than wait on confirmation. The Welders get notified on the commencements.
DESIGN GOAL: FLEXIBLE
USER SCENARIO
Improper bin management -> Improper inventory tracking -> Delay in placing the order. The requirement (quantity and type) of the parts are sporadic and depends on the PO. Third party company was unable to guarantee timely supply:
Request is more than allocated when they have limited stock.
Rise of requests in an unfavourable times.
SOLUTION
Based on the production orders upcoming or current cycles, with AI suggestions user can alert on requirements vendors. once they get confirmation from them they place an order with them
Learning
It’s a huge privilege to get ownership of a project where I was able to take advantage of my past experience working at a manufacturing unit as this is one of my products I’ve have delivered with end-to-end solution.
Implementing design system with various component states
We would have iterated more component states to explore the digital real estate and further expanded the AI integration for improved suggestions.
Ways to in-corporate the PO into the system to track at a granular level - the usage of parts.
For our vision based solution, another possible approach would be using image processing using open cv technology. This would have helped us get us real time data with parameter (frequency of parts usage, set different threshold values for each part and etc). In turn, our data analytics would have been more accurate to determine timely availability of these parts and avoid any order issues.
That's me giving demo and briefing on the next steps to the clients
If you have any more questions or want to know more details, please don't hesitate to contact me. For now, please consider checking my other work, my experiments, or learn more about me.
