Modernizing a Legacy Steel Production System
Project Summary
Client
Domain
Role
​Users
Tools
: Leading Steel Manufacturing Company
: Industrial Process Management / Manufacturing
: Senior Technical Lead – UX Design (Responsible for User Research, Usability and Prototyping)
: Production Plant Engineers and Support staff managing steel processes
: Figma
Business Objective
Modernize a legacy system to improve usability, eliminate workflow friction, accelerate operational efficiency, ensure data accuracy, and boost employee satisfaction and retention.
User Interiews
User Roles Involved in this project
-
Production Plant Engineers – Optimising technical processes and Analysing system performance
-
Production Supervisors – Monitor real-time progress and manage production schedules.
-
Shift Operators – Input data, Track machinery status, and log production events.
-
Quality Control Inspectors – Review and validate steel quality parameters.
-
Maintenance Personnel – Log equipment issues and downtime reports.
Problem Statement
The lack of a batch update feature in the legacy system delays coil processing by up to 40%, reduces popup, and drives unnecessary labor costs.
User Roles Involved associated with this problem statement
-
Production Supervisors – Monitor real-time progress and manage production schedules.
-
Shift Operators – Input data, Track machinery status, and log production events.
-
Quality Control Inspectors – Review and validate steel quality parameters.
A closer look at our key user persona reveals where the batch update pain points emerged
-
Shift Operators – Input data, Track machinery status, and log production events.
Shift Operators - persona
Name: Ravi Kumar
Age: 38
Role: Steel Coil Processing Operator
Experience: 12 years in steel manufacturing
Location: Bellary, Karnataka, India​
​
Background
Ravi works in the coil processing section of the steel plant. His primary job is to record coil measurements, weights, inspection results, and defect details after each stage of processing. the legacy system he used was slow, cluttered, and required repetitive data entry, often resulting in frustration and delays.
​
Goals
-
Quickly record coil data without unnecessary navigation between screens.
-
Minimize repetitive entries for batch updates.
-
Reduce downtime during system errors or slow loading.
-
Ensure accuracy in inspection results and defect reporting.
​
Pain Points
-
Repetitive Data Entry: Had to enter the same measurement multiple times for multiple coils.
-
Complex Navigation: Too many screens to switch between for a single task.
-
Slow System Response: Lag during high production hours caused work backlog.
-
Limited Error Handling: No quick way to correct or update multiple entries at once.
-
Low Visual Clarity: Important input fields were buried among less-used options.
​
Motivations
-
Keep production line moving without bottlenecks.
-
Maintain high accuracy to avoid product rejection.
-
Reduce mental fatigue from repetitive tasks.
​
Technical Comfort Level
-
Comfortable with basic industrial software.
-
Needs clear, simple, and consistent UI for efficiency.
​
Quote
“If I could update all coil details at once, I’d finish my job faster and focus on quality rather than fighting the system.”
.
User Survey
A focused survey with shift operators gathered insights on workflow challenges, data entry issues, and usability gaps in the batch update process. The findings aimed to guide system modernization, streamline operations, and boost productivity.
User Survey Questions and Feedback for Quantitative Result
-
​​How often do you perform batch updates in a single shift?
-
Which part of the batch update process do you find most time-consuming?
-
How accurate do you feel the current coil measurement and weight data entry process is?
-
When entering inspection results, what challenges do you face?
-
How easy is it to navigate the current system to find the coil you need to update?
-
Do you use any workarounds (paper notes, Excel, verbal communication) before entering data in the system?
-
How often do you face delays due to system downtime or slow loading?
-
What task in the update process do you find yourself repeating the most often?
-
Do you find pop-up windows helpful or distracting?
-
Are fonts, buttons, and colours easy to read and use?
-
How satisfied are you with the current batch update process overall?
-
Is the system easy to learn and operate?
Modernizing a Legacy Steel Production System
Project Summary
Client
Domain
Role
​Users
Tools
: Leading Steel Manufacturing Company
: Industrial Process Management / Manufacturing
: Senior Technical Lead – UX Design (Responsible for User Research, Usability and Prototyping)
: Production Plant Engineers and Support staff managing steel processes
: Figma
Business Objective
Modernize a legacy system to improve usability, eliminate workflow friction, accelerate operational efficiency, ensure data accuracy, and boost employee satisfaction and retention.
Problem Statement
The lack of a batch update feature in the legacy system delays coil processing by up to 40%, reduces throughput, and drives unnecessary labor costs.
User Interiews
Context of Problem Statement
Batch update allows operators to update multiple coils at once for data like measurements, weights, and inspection results. In the legacy system, each coil had to be updated individually across multiple screens, requiring repeated entries and excessive clicks. This slowed coil processing by up to 40%, reduced throughput, and increased labor costs due to redundant work.
User Roles Involved in this project
-
Production Plant Engineers – Optimising technical processes and Analysing system performance
-
Production Supervisors – Monitor real-time progress and manage production schedules.
-
Shift Operators – Input data, Track machinery status, and log production events.
-
Quality Control Inspectors – Review and validate steel quality parameters.
-
Maintenance Personnel – Log equipment issues and downtime reports.
User Roles Involved associated with this problem statement
-
Production Supervisors (Secondary Persona) – Monitor real-time progress and manage production schedules.
-
Shift Operators (Primary Persona) – Input data, Track machinery status, and log production events.
-
Quality Control Inspectors (Secondary Persona) – Review and validate steel quality parameters.
A closer look at our primary persona reveals where the batch update pain points emerged
-
Shift Operators Primary Persona) – Input data, Track machinery status, and log production events.
Shift Operators - persona
Name: Ravi Kumar
Age: 38
Role: Steel Coil Processing Operator
Experience: 12 years in steel manufacturing
Location: Bellary, Karnataka, India​
​
Background
Ravi works in the coil processing section of the steel plant. His primary job is to record coil measurements, weights, inspection results, and defect details after each stage of processing. the legacy system he used was slow, cluttered, and required repetitive data entry, often resulting in frustration and delays.
​
Goals
-
Quickly record coil data without unnecessary navigation between screens.
-
Minimize repetitive entries for batch updates.
-
Reduce downtime during system errors or slow loading.
-
Ensure accuracy in inspection results and defect reporting.
​
Pain Points
-
Repetitive Data Entry: Had to enter the same measurement multiple times for multiple coils.
-
Complex Navigation: Too many screens to switch between for a single task.
-
Slow System Response: Lag during high production hours caused work backlog.
-
Limited Error Handling: No quick way to correct or update multiple entries at once.
-
Low Visual Clarity: Important input fields were buried among less-used options.
​
Motivations
-
Keep production line moving without bottlenecks.
-
Maintain high accuracy to avoid product rejection.
-
Reduce mental fatigue from repetitive tasks.
​
Technical Comfort Level
-
Comfortable with basic industrial software.
-
Needs clear, simple, and consistent UI for efficiency.
​
Quote
“If I could update all coil details at once, I’d finish my job faster and focus on quality rather than fighting the system.”
.
User Survey
A focused survey with shift operators gathered insights on workflow challenges, data entry issues, and usability gaps in the batch update process. The findings aimed to guide system modernization, streamline operations, and boost productivity.
User Survey Questions and Feedback for Quantitative Result
-
​​How often do you perform batch updates in a single shift?
-
Which part of the batch update process do you find most time-consuming?
-
How accurate do you feel the current coil measurement and weight data entry process is?
-
When entering inspection results, what challenges do you face?
-
How easy is it to navigate the current system to find the coil you need to update?
-
Do you use any workarounds (paper notes, Excel, verbal communication) before entering data in the system?
-
How often do you face delays due to system downtime or slow loading?
-
What task in the update process do you find yourself repeating the most often?
-
Do you find pop-up windows helpful or distracting?
-
Are fonts, buttons, and colours easy to read and use?
-
How satisfied are you with the current batch update process overall?
-
Is the system easy to learn and operate?
