SafeWork
Smart Devices
Contribution
Industrial Design
UX/UI Design
Wearable Design
Smart docking Station, Sensor, and Wearables for Safety & Injury Prevention
How does it work?
Docking system with a built-in app to manage the sensor deployment and data collection.
Sensor to collect the motion & environment data.
Wearable to provide a comfortable way to wear the sensor while working.
Each component must be compatible with the other, and they should not interfere with the user’s day-to-day work routine. The anticipated deployment sites are environments like warehouses, distribution centers, and loading zones.
Background
An average of 38,812 occupational injuries occur worldwide in logistics, warehouses, distribution centers, and retailers every hour.
I worked with CEO and CPO to identify the high-level problems and came up with the safety system.
The system requires a dock with a screen, sensor, and wearable and each component needs to be compatible with the whole system.
The system must be easily installed and used in the workplaces such as warehouses, plants, and distribution centers.
Target Users: Industrial Athletes
The Industrial Athletes™ is the essential, frontline workers of the world who put their bodies on the line day in and day out. Their primary goals are completing their tasks efficiently and getting home without injuries.
- StrongArm Technologies
Based on the targeted user, I created a user persona to identify the characteristics and develop the best design solutions.
User Persona
George, Associate
George started working at the distribution center at age 20 to support his financial needs.
He wants to finish the job on time and leave on time. He heard about with some smart devices but never had any experience using them.
Struggling to get used to the job he/she never had before but trying to complete the job.
Applied for the job to support his immediate expenses.
Never had any safety awareness training before.
Age: 20-25
Experience level: Less than a year
Avg. Shift Hours: 5-8
Education: High school
Language: English, Spanish
Rob, Supervisor
Rob became a supervisor after his 4 years of working experience in the facility.
He is a veteran of operations in his workplace and knows what to do.
He used a couple of smart devices but doesn’t really trust these.
Age: 33-54
Experience level: 4-5+ years
Avg. Shift Hours: 8+
Education: High school
Language: English, Spanish
Started as an associate level and got promoted.
Trying to meet the daily production quota.
Knows basic operations and how things work in their workplace.
The Discovery
I conducted research by doing an onsite visit & observation and 1: 1 user interviews to learn more about the users.
All the ideas come from understanding user behaviors and where the potential design opportunities lie.
Checking in at the front before the shift begins
The supervisor gathers the employees and does the daily brief
Everyone does the daily body stretching to warm up
Each employee goes to their assigned area to begin their work
I learned that most employees’ task is very repetitive and use their body movement a lot. They also want to quickly finish their job and leave on time without any hassles.
Userflow
Design process
Based on the research and findings, leadership initiated the product development, and My major role varied with each device.
Sensor + Smart Dock
Ideating
With the given requirements, my focuses were on the sensor designs that can be worn with/without the wearables. Also, they need to be easily picked up from the smart dock and should have a simple UI to indicate the status.
The sensor also requires to have features like haptic feedback and collecting environmental data such as temperature, humidity, and lights.
Sensors also need to be working seamlessly with wearables to be worn by industrial athletes.
3D Realization & Prototyping
I also turn 2-dimensional ideas into 3-dimensional to study the actual form factors and the mechanical limitations.
I did a quick CAD modeling to create different iterations of the sensor designs. 3D printed models helped to develop the details of the physical form and functions.
After I developed the initial form of the hardware, I worked with the embedded and hardware engineering team to develop the final design.
Validation Process & Onsite Testing
I worked with the production and hardware engineering teams to go through EVT, DVT, and PVT processes for scaled production.
During the initial production phase, the team rolled out a series of scaled deployments to the customer’s sites to test from 50 to 100+ user groups at the customer’s site.
From these deployments, the team collected both qualitative and quantitative feedback that was applied to the improvement of the minor design issues before making the final tooling and ordering the electronics.
Dock App UX/UI
Wireframing & User Flow
I created the wireframe to learn and understand the basic check-out flow of the sensors on the dock. The goal was to create a UI that can be easily understood and quickly. Because users didn’t want to spend a lot of time checking out their sensors before shift begins.
The smart dock was going to have its own built-in tablet operated in Android. The screen size was 8“ so I have to consider the accessibility due to the nature of where the smart dock was going to be set up.
Dock App Design System & Prototyping
I used the real smart dock tablet with a digital prototype tool installed in order to understand the in-person experience and test my UI designs. My focuses were the speed of the check-out process and accessibility. These are important because the main goal is not to interrupt the user’s daily work routine.
I also created the Dock App Design System optimized for the user experience of touch screen interaction. Screen size was
User Testing
Along with the initial deployment of the system to the site, I was able to perform in-person user testing and observation. The scale of user testing was from small (5-10 people) to large (50-100 people) depending on the customer and site scale.
Based on the user feedback, I made several design adjustments addressing minor accessibility issues.
Wearable
Research & Ideating
My main design focus for wearables is comfortability that covers diverse body types. It is because not a lot of people are used to wearing an extra thing on top of what they wear during the shift.
After the initial discussion with the customer team, I had several meetings with customers to gather what would be the optimal options for the wearables. We decided to explore three garments - A shoulder harness, a safety vest, and a slim backpack-style harness.
Prototyping
After the team decided on the garment options, I started to make prototypes of garments to understand the technical structure and how they feel when you wear them.
I also searched through different materials that are sweat-wicking, flexible, and have enough durability.
In order to do the initial user testing, I created 20-30 prototypes of each garment.
Onsite Testing & Production
I set up the testing plan that 1 user to try all 3 different garments each week and then compare them to gather feedback on each. Initial testing was done on several customer sites.
The testing was done within 3 weeks to try all 3 different options. I was able to gather some minor feedback regarding the adjustment and comfort issues that helped me to make improvements before I made production-ready designs.
I created the tech pack and worked with the product manager to find sourcing vendors who can produce the wearables with the right materials in the given timeframe.
Final SafeWork System
How does it work?
Smart Dock Design
The final smart dock has 25 sensors to be working with. It is installed in the warehouse or related industrial space for users to check out and use the sensors during their shifts.
Built-in touch screen tablets helps users to go through step by step check-out process and be able to access their safety data or tips.
Dock App
The main dock app is focused on checking out sensors. So I minimized the number of screens that the user sees yet provide clear information about what is going on and how to interact to check out the sensors.
Setup Wizard
This process shows up when the user turns on the smart dock for the first time. I simplified the steps with minimal interactions and requirements. However, there were some mandatory steps that the user needs to follow so I designed some of the screen to be succint and easy to understand.
Sensor Designs
FUSE V5
Collects ergonomic data to be sent out to the database
Integrated temperature and proximity sensor
Added the OLED display to show detailed information
Added the color LED light bars to indicate the status of the sensor
Worn with shoulder harness, or could be put in the pockets
FLEX
Collects ergonomic data to be sent out to the database
Integrated temperature and proximity sensor
Added the color LED light bars to indicate the status of the sensor
Worn with designated wearable OR its clip to proper areas
Wearable Design
Different types of wearables provide extended options that users can choose to wear for their comfort while collecting the data precisely. This helped to increase 2-3x the user’s adaption to the SafeWork System.
X-Pack
X-Pack is designed to give a user have ‘backpack-like’ experience. The entire wearable is constructed with breathable, stretchable, and light materials to maximize comfortability. And this was the most favorite option that users loved.
This wearable increased user adaption and engagement by 2-3X.
FUSE Shoulder Harness
This wearable is specifically designed to adapt the FUSE V5 to the most ideal body position for data accuracy.
The harness is constructed with durable materials to protect from any potential wear from the harsh environment.
Safety Vest
The design team also created the integrated system onto a conventional safety vest to maximize visual safety and yet doesn’t interfere with the user’s work activities.
Impact
The Devices Reduced Workplace Injuries by up to 52%
After the successful phased deployments of the system to 10+ customer sites, the SafeWork System helped companies to reduce workplace injuries by up to 52% year-over-year.
