Creating a visual factory for the production line at Tecan
Transformed paper-based assembly instructions into a digital workflow that improved speed, traceability, and consistency for a medtech robotics company at the height of the COVID-19 pandemic.
Creating a visual factory for the production line at Tecan
Transformed paper-based assembly instructions into a digital workflow that improved speed, traceability, and consistency for a medtech robotics company at the height of the COVID-19 pandemic.
Creating a visual factory for the production line at Tecan
Transformed paper-based assembly instructions into a digital workflow that improved speed, traceability, and consistency for a medtech robotics company at the height of the COVID-19 pandemic.
Overview
Tecan Group is a global provider of laboratory instruments and automation solutions. Within the bio-lab manufacturing division, I worked with production personnel and Manufacturing Engineers to redesign the assembly process through user-centered design practices.
Objective
Transform written assembly instructions and CAD drawings into a digital “Visual Factory” platform to improve line efficiency and reduce production errors.
Role & Duration
Needfinding · User Research · Usability Testing · Information Architecture
Oct 2019 - Oct 2020
Overview
At NVIDIA, I worked on improving a core workflow used by teams developing and deploying machine learning models
Objective
Transform written assembly instructions and CAD drawings into a digital “Visual Factory” platform to improve line efficiency and reduce production errors.
Role & Duration
Needfinding · User Research · Usability Testing · Information Architecture
Oct 2019 - Oct 2020
The Challenge
Production lines relied heavily on printed instructions and manual verification, leading to inconsistencies and delays. Operators had developed informal methods over time, creating variations in assembly accuracy and documentation.
Key issues:
• Inconsistent operator methods
• Paper-based verification added friction
• Outdated hard-copy instructions
• Limited checkpoints for accountability
Design prompt:
How might we reduce production errors and improve efficiency through digital line tracing and visual aids?
The Challenge
Production lines relied heavily on printed instructions and manual verification, leading to inconsistencies and delays. Operators had developed informal methods over time, creating variations in assembly accuracy and documentation.
Key issues:
• Inconsistent operator methods
• Paper-based verification added friction
• Outdated hard-copy instructions
• Limited checkpoints for accountability
Design prompt:
How might we reduce production errors and improve efficiency through digital line tracing and visual aids?
The Process
Human-Centered Research
We began with deep listening — conversational interviews with survivors in clinic waiting rooms and dedicated sessions with oncologists and nurses. Our research plan emphasized empathy and psychological safety, allowing emotion and openness to guide discussion.
Human-Centered Research
We began with deep listening — conversational interviews with survivors in clinic waiting rooms and dedicated sessions with oncologists and nurses. Our research plan emphasized empathy and psychological safety, allowing emotion and openness to guide discussion.
Human-Centered Research
We began with deep listening — conversational interviews with survivors in clinic waiting rooms and dedicated sessions with oncologists and nurses. Our research plan emphasized empathy and psychological safety, allowing emotion and openness to guide discussion.
Second year at the company with responsibilities on multiple lines in production. Updated work instructions are the last thing on his mind while he puts out first on the production floor. Assembly errors require time for re-works, which means lower production rates.
Goal: To minimize production errors
Frustrations: - Sepearate WI documents created at different times make it difficult to update and maintain - Can't track production or hold operator accountability - Assembly errors lead to lower output per line
William (40)
Manufacturing Engineer
New to the production floor with experience in tool handling and minor mechanical work. Needs to run through the assembly process slowly in order to get a handle on things. Unfamiliar with varying builds on a single line due to customer-specific products.
Goal: To learn the assemly process with minimal confusion and production errors
Frustrations: - Language barrier - Unfamiliar with assembly process - Flipping through work intructions is too time consuming
Frank (30)
Inexperienced Operator
Years of experience under her belt with time spent on multiple different lines, building a variety of products. Executes batch-style assmebly and no error checking in order to speed up production. Rarely opens and refers to work instructions.
Goal: To work quickly and error-free while understanding the current build at all times
Frustrations: - Too much production paperwork - Wants to move quickly through the assmebly - Unreliable and dense work instructions
Kim (55)
Experienced Operator
Goal
To minimize production errors
Frustrations
Separate WI documents created at different times make it difficult to update and maintain
Can't track production or hold operator accountability
Assembly errors lead to lower output per line
William (40)
Manufacturing Engineer
Goal
To learn the assembly process with minimal confusion and production errors
Frustrations
Language barrier
Unfamiliar with assembly process
Flipping through work instructions is too time consuming
Frank (30)
Inexperienced Operator
Goal
To work quickly and error-free while understanding the current build at all times
Frustrations
Too much production paperwork
Wants to move quickly through the assembly
Unreliable and dense work instructions
Kim (55)
Experienced Operator
Research & Discovery
I embedded myself on the production floor to observe workflows firsthand — shadowing operators, conducting informal interviews, and testing prototypes directly with end users.
Design & Iteration
Early iterations focused on digitizing the most error-prone steps and streamlining verification. The Visual Factory platform integrated digital instructions, embedded CAD visuals, and real-time checkpoints to improve traceability.
Remote Collaboration
Transitioning to remote work during COVID-19 limited direct user access, so I leaned on observational data and iterative reviews with the Manufacturing Engineering Manager to refine usability and flow.
Second year at the company with responsibilities on multiple lines in production. Updated work instructions are the last thing on his mind while he puts out first on the production floor. Assembly errors require time for re-works, which means lower production rates.
Goal: To minimize production errors
Frustrations: - Sepearate WI documents created at different times make it difficult to update and maintain - Can't track production or hold operator accountability - Assembly errors lead to lower output per line
William (40)
Manufacturing Engineer
New to the production floor with experience in tool handling and minor mechanical work. Needs to run through the assembly process slowly in order to get a handle on things. Unfamiliar with varying builds on a single line due to customer-specific products.
Goal: To learn the assemly process with minimal confusion and production errors
Frustrations: - Language barrier - Unfamiliar with assembly process - Flipping through work intructions is too time consuming
Frank (30)
Inexperienced Operator
Years of experience under her belt with time spent on multiple different lines, building a variety of products. Executes batch-style assmebly and no error checking in order to speed up production. Rarely opens and refers to work instructions.
Goal: To work quickly and error-free while understanding the current build at all times
Frustrations: - Too much production paperwork - Wants to move quickly through the assmebly - Unreliable and dense work instructions
Kim (55)
Experienced Operator
The Process
Human-Centered Research
We began with deep listening — conversational interviews with survivors in clinic waiting rooms and dedicated sessions with oncologists and nurses. Our research plan emphasized empathy and psychological safety, allowing emotion and openness to guide discussion.
Human-Centered Research
We began with deep listening — conversational interviews with survivors in clinic waiting rooms and dedicated sessions with oncologists and nurses. Our research plan emphasized empathy and psychological safety, allowing emotion and openness to guide discussion.
Human-Centered Research
We began with deep listening — conversational interviews with survivors in clinic waiting rooms and dedicated sessions with oncologists and nurses. Our research plan emphasized empathy and psychological safety, allowing emotion and openness to guide discussion.
Second year at the company with responsibilities on multiple lines in production. Updated work instructions are the last thing on his mind while he puts out first on the production floor. Assembly errors require time for re-works, which means lower production rates.
Goal: To minimize production errors
Frustrations: - Sepearate WI documents created at different times make it difficult to update and maintain - Can't track production or hold operator accountability - Assembly errors lead to lower output per line
William (40)
Manufacturing Engineer
New to the production floor with experience in tool handling and minor mechanical work. Needs to run through the assembly process slowly in order to get a handle on things. Unfamiliar with varying builds on a single line due to customer-specific products.
Goal: To learn the assemly process with minimal confusion and production errors
Frustrations: - Language barrier - Unfamiliar with assembly process - Flipping through work intructions is too time consuming
Frank (30)
Inexperienced Operator
Years of experience under her belt with time spent on multiple different lines, building a variety of products. Executes batch-style assmebly and no error checking in order to speed up production. Rarely opens and refers to work instructions.
Goal: To work quickly and error-free while understanding the current build at all times
Frustrations: - Too much production paperwork - Wants to move quickly through the assmebly - Unreliable and dense work instructions
Kim (55)
Experienced Operator
Goal
To minimize production errors
Frustrations
Separate WI documents created at different times make it difficult to update and maintain
Can't track production or hold operator accountability
Assembly errors lead to lower output per line
William (40)
Manufacturing Engineer
Goal
To learn the assembly process with minimal confusion and production errors
Frustrations
Language barrier
Unfamiliar with assembly process
Flipping through work instructions is too time consuming
Frank (30)
Inexperienced Operator
Goal
To work quickly and error-free while understanding the current build at all times
Frustrations
Too much production paperwork
Wants to move quickly through the assembly
Unreliable and dense work instructions
Kim (55)
Experienced Operator
Research & Discovery
I embedded myself on the production floor to observe workflows firsthand — shadowing operators, conducting informal interviews, and testing prototypes directly with end users.
Design & Iteration
Early iterations focused on digitizing the most error-prone steps and streamlining verification. The Visual Factory platform integrated digital instructions, embedded CAD visuals, and real-time checkpoints to improve traceability.
Remote Collaboration
Transitioning to remote work during COVID-19 limited direct user access, so I leaned on observational data and iterative reviews with the Manufacturing Engineering Manager to refine usability and flow.
Second year at the company with responsibilities on multiple lines in production. Updated work instructions are the last thing on his mind while he puts out first on the production floor. Assembly errors require time for re-works, which means lower production rates.
Goal: To minimize production errors
Frustrations: - Sepearate WI documents created at different times make it difficult to update and maintain - Can't track production or hold operator accountability - Assembly errors lead to lower output per line
William (40)
Manufacturing Engineer
New to the production floor with experience in tool handling and minor mechanical work. Needs to run through the assembly process slowly in order to get a handle on things. Unfamiliar with varying builds on a single line due to customer-specific products.
Goal: To learn the assemly process with minimal confusion and production errors
Frustrations: - Language barrier - Unfamiliar with assembly process - Flipping through work intructions is too time consuming
Frank (30)
Inexperienced Operator
Years of experience under her belt with time spent on multiple different lines, building a variety of products. Executes batch-style assmebly and no error checking in order to speed up production. Rarely opens and refers to work instructions.
Goal: To work quickly and error-free while understanding the current build at all times
Frustrations: - Too much production paperwork - Wants to move quickly through the assmebly - Unreliable and dense work instructions
Kim (55)
Experienced Operator
The Solution
The redesigned Visual Factory replaced static documents with interactive digital instructions that provided visual cues, progress tracking, and clearer accountability.
Core improvements:
Modular instruction flow by assembly step
Embedded CAD visuals for context
Built-in verification checkpoints to reduce batching errors
The Solution
The redesigned Visual Factory replaced static documents with interactive digital instructions that provided visual cues, progress tracking, and clearer accountability.
Core improvements:
Modular instruction flow by assembly step
Embedded CAD visuals for context
Built-in verification checkpoints to reduce batching errors
The Reflection
Working at Tecan was a formative experience in bridging user research and manufacturing design.
I learned the importance of proximity to users, adaptability when access is limited, and the power of visual clarity in high-stakes production environments.
Contributing to a company that supported medical labs during the COVID-19 pandemic was both humbling and motivating — reinforcing my desire to design systems that make a tangible impact.
The Reflection
Working at Tecan was a formative experience in bridging user research and manufacturing design.
I learned the importance of proximity to users, adaptability when access is limited, and the power of visual clarity in high-stakes production environments.
Contributing to a company that supported medical labs during the COVID-19 pandemic was both humbling and motivating — reinforcing my desire to design systems that make a tangible impact.
