Accelerating steel production by 20% with better UX

How we improved the experience and drove efficiency for a large steel manufacturing company.

Manufacturing Case Study

Introduction

A large steel manufacturing company, with divisions throughout the North America, uses internally-built software to prepare production staff with dimensions, load characteristics, and other characteristics like beam sizes. All of this data is produced from simple 2D drawings produced and shared by engineering firms working on behalf of familiar big-box retailers.

This software ballooned into a fairly complex tool used by nearly 100 team members, with an array of complaints ranging from the tool's slow performance, to specific issues in the workflow with the tool.

Early insights

We came up with a handful of themes from the experience audit:

  • It's too hard for a structural engineer to select a series of plan components based on design criteria
  • The tool lacks important visual cues to signal which actions should be taken next
  • Users tend to need to switch between multiple tabs/screens to complete their work
  • Each division spread throughout North America tends to have its own unique process

By the numbers

With 3 major US holidays bearing down on us, we got to work quickly by scheduling and conducting user interviews with designated subject matter experts fluent in the current process. This revealed a number of pain points in the current process.

By pairing this knowledge with an understanding of the already-planned features in the incoming replacement tool, we produced a series of recommendations, artifacts, and prototypes for the team to incorporate into the replacement tool's roadmap.

During this phase, we produced:

  • 3 personas to distill key tasks, pain points and motivations of certain types of users
  • A journey map to clearly outline the steps involved in a user's completion of common tasks
  • 9 highly-detailed features with user stories to describe specific changes or new functionality
  • Over 80 high-fidelity wireframes to show the features and how they work
  • 4 interactive prototypes to allow stakeholders to explore how the features work in the tool

The outcome

Through our work, the client is realizing up to a 20% reduction in the time it takes design engineers to complete their tasks, which is to $500K in annual savings from efficiency gains.

Through this project we helped guide the client to understand:

  1. Make it easier to interpret information quickly. The more users can quickly glance at and make selections, the faster they can complete their work.
  2. Remove unnecessary steps. Combine multiple existing and new features in a way that improves focus.
  3. Allow for customizations. Each division has its own slightly-altered process that should be gradually more accommodated by the tool.
  4. Apply UX best practices. A few simple things to keep in mind, like visual hierarchy, will help the team to continue evolving the tool with users in mind.

In summary, through our partnership the steel manufacturer is saving significant time and energy, has a better understanding of UX best practices, and is well positioned for further growth and enhancement.

Faster turnaround times
20%
Users surveyed
83
Potential revenue increase
$470K+

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