Project overview:
This initiative addressed the outdated, error-prone paper-based Worker Tracking List used in factories to assign workers and vendors to machines. The primary mission was to enhance worker safety by digitizing an outdated paper tracking system into a clear, reliable digital tool that reduced human error, improved worker safety, and boosted operational efficiency during high-pressure factory scenarios.
Problem statement:
Outdated paper Worker Tracking Lists caused errors, delays, and safety risks during high-pressure maintenance. The challenge was to digitize this system, improving accuracy, situational awareness, and enabling managers and workers to act quickly and confidently under pressure.
Challenges / Approach
FACING THE CHALLENGE:
Designing a system for high-stakes factory operations required deep understanding of frontline workflows, safety concerns, and real-time accountability.
- Paper lists were easily misplaced or illegible due to inconsistent handwriting or mismatched fields.
- Confusion and delays during maintenance scenarios created real safety risks, particularly during emergencies such as plant outages.
- The challenge was to create a reliable digital tool that ensured accurate tracking, improved situational awareness, and supported rapid decision-making under pressure.
How I overcame It:
- Conducted “workout sessions” with Maintenance Managers to uncover pain points under stress.
- Identified key requirements: clarity, legibility, and real-time accountability.
- Designed and visualized a digital Worker Tracking List that improved traceability and situational awareness.
- Transitioned processes from manual, error-prone methods to a digital system that supports safer and more reliable operations.
Results:
- Enhanced worker safety by eliminating critical errors caused by illegible or lost paperwork.
- Improved operational efficiency, especially during emergency maintenance scenarios.
- Delivered a solution that brought clarity and peace of mind to managers under pressure, enabling them to focus on decisions rather than paperwork.
The Worker Tracker is now actively used in our client’s operations, reducing errors, improving safety, and streamlining critical workflows. This success demonstrates the tangible value of our design, proving how thoughtful digital solutions can directly impact efficiency and worker well-being. I take pride in knowing my work not only modernized an outdated system but also delivered measurable improvements that support the client’s long-term success.
Boris is one of, if not the most, talented designer I have come across in my career. What sets Boris apart from his amazing design skills is his unique ability to communicate and articulate his creative vision with senior leadership. He has a keen sense of problem solving for end users. An extremely high say/do ratio and his work speaks for itself. His personality and ability to work with a diverse set of team members is what makes him a highly sought after designer.
