Learning Launch of an Automated Guidance/Validation Tool

Challenge

I work in a high-tech manufacturing environment. A few years ago, we were faced with escalations from  our customers about failures in shipped product. A small team was formed to investigate the issues and  implement corrective actions. The team analyzed all the issues in detail to see if there are any systemic  root causes. The findings were compiled and presented. It was noticed that there were inconsistencies  in the manufacturing and validation processes that were being used. We noticed that even experienced  personnel had a tough time to keep up with the complex requirements and specifications of building the  product. Newly hired personnel were struggling to follow instructions, calculating specifications,  interpreting results, and ensuring highest quality of shipped product.

We needed to build a tool that will help personnel, irrespective of their experience, to build complex  assemblies with ease. We had to change the way we were doing things. Change is not easy - we needed  buy in. We need to build something that both experienced and new people like. The solution should be  scalable and at the same time make economic sense.

Selection

Design is an Iterative process. It might take years to perfect a product. But in the high tech work we  need to be quick to market. We need to get buy in from all the stake holders fast. We need to convince  management to Invest based on reliable good data.

A colleague and I started to work on this problem. We both had a lot of experience (breadth) in the  manufacturing domain. We have worked in this area for years and were able to think through the  details. We also had decent programming skills that were needed to develop something that we could  test out. We decided to quickly build something and do a Learning Launch.

Application

We started to work on a Minimum Viable Product (MVP). We developed basic functionality using C#  coding. The application was completely a simulation. It would simulate build scenario and guide  users/personnel to follow step by step instructions on how to proceed. It will automate processes when  it can, make decisions for users and provide valuable insight into the process. Even though it was  completely a simulation - it was very visual and provided a rich experience for the users to try it out.

We recruited a few Testers to try out the application. We carefully selected people based on different  levels of experience and skill sets. We asked them to try out the product for a few hours. We partnered  with the testers and carefully collected their feedback – How long did it take to complete, What they  liked, What they did not like. We also collected data on their progress through the application –  compared and contrasted data - based on their levels of experience. We carefully tabulated all the data  and extrapolated it to the real word scenario. The results & lessons learned were peer reviewed and  shared with management.

Insight

The feedback and data collected was very helpful. It clearly showed the need and the value of  developing a tool like this. We were able to understand what experienced users were looking for (more

automation) and what new users were looking for (detailed guidance). We now knew we had to develop  something that can be customized based on user experience. We were able to collect data on savings.  Now we could create a ROI model for management decision to proceed with full-fledged development.  We were also able to show end users what the app might look like – will eventually help us get the buy  in. We got some insights on what data is important, how it should be collected and stored. We were  analyzed Scalability needs and came up with resource needs - Systems, People, Budget etc.

Approach

I think this approach of use Learning Launch was the right one and it yielded fantastic results. We can  expand the launch now across other business groups to learn more and improve. Every time we will  learn something new, get new data, gain useful insights and better the product. The data collected  during this Learning launch was used to create a compelling story (Story telling) for management buy in  and investments.

