Quality Checks, Quality Assured!
Role
User Experience and Design Lead
Industry
Automobile
Duration
5 months
The Brief
The current quality control/check (QC) process relies heavily on manual paper-based documentation, which poses challenges in terms of efficiency and accuracy. Also, for legal purposes these documents have to be kept for upto 15 years. We seek to modernise and streamline this process by transitioning to an online platform, leveraging IoT technology at its core. The goal is to digitise the QC process for each station in our plants, ensuring flexibility to accommodate various scenarios. Additionally, we require a comprehensive dashboard accessible to team leaders, managers, and business stakeholders, providing real-time insights to enhance decision-making. Moreover, we need a robust backend system to support seamless integration of process upgrades and hardware enhancements. This initiative aims to improve the efficiency and effectiveness of our QC process, driving operational excellence and quality assurance throughout our manufacturing operations.
The Challenges
Cross-Departmental Impact:
Any updates to processes within the plant have ripple effects across multiple departments, requiring careful coordination and communication.Multifaceted Operations:
As India's largest car manufacturer, managing multiple plants across different locations with various production lines and distinct vehicle requirements adds complexity to the standardization of QC processes.Customised Dashboard Information:
Catering to the diverse needs of different user groups within the organization necessitates the creation of customized information sets within the dashboard.Future-Proof Backend System:
Developing a backend system that can adapt to future process upgrades and evolving technological requirements is essential for long-term sustainability and scalability.
The Approach
Our approach to transforming the Quality Control (QC) process involved a comprehensive analysis of current workflows and data management methods. We began by documenting all steps in the QC line, identifying data retrieval methods, and understanding legal requirements. Collaboration with cross-functional teams ensured that the digitization process addressed the specific needs of each station, enhancing efficiency and accuracy. Through iterative prototyping and rigorous testing, we developed a scalable and user-friendly digital platform that streamlined QC operations across multiple plants.
Finding a starting point
Document all steps in the QC line at the plant.
Document data retrieval methods from machines and manual data entry points at each station.
Document possible outcomes at each station and associated procedures.
Document legal requirements and approval chains for each station.
Follow up
Identify data requirements for supervisors and managers.
Consider both reporting needs and display on the dashboard.
Ensure alignment with business objectives and user needs.
Being thorough
Create a user journey for the mobile application used by line operators and other plant workers.
Define data sets generated by the app for dashboard placement.
Develop a user management requirements chart.
Putting Pen to Paper
Develop high-fidelity wireframes and prototypes specifically for the mobile application.
Ensure that the design allows for flexibility and scalability to accommodate future upgrades and expansions.
Conduct thorough testing of the prototypes on all stations with designated hardware to ensure compatibility and functionality.
Develop high-fidelity wireframes for the backend based on the finalised data from the mobile application
Implement user flows for other plant machineries and relevant processes, considering future upgrades.
Design wireframes for all dashboard versions based on access management.
Ensure adaptability and flexibility to future requirements.
Outcome
The implementation of the digital Quality Control (QC) platform resulted in a significant increase in operational efficiency and accuracy across multiple plants. The streamlined data management process reduced errors and compliance issues, while the intuitive interface improved user adoption and satisfaction. The project successfully digitised previously manual workflows, leading to faster QC processing times and enhanced overall productivity. Client feedback highlighted the platform’s scalability and its positive impact on maintaining consistent quality standards.
