Interactive Parts System

Fragmented guidance for a complex assembly

Q-Bot's installation teams rely on a spray nozzle composed of a complex multi-part assembly, used in real-world field conditions.

Installers had limited and fragmented reference materials:

• Small printed exploded diagrams attached to toolboxes
• A 90-row spreadsheet used to identify and order parts

This created a disconnect between:

• The physical assembly process
• The way information was structured and accessed

As a result, mis-assemblies and incorrect part orders were common, directly impacting operational performance.

A self-reinforcing fault loop

Frequent nozzle faults were not isolated issues - they were the result of a negative reinforcing loop: errors → downtime → incorrect fixes → repeated errors.

The core challenge was not just improving instructions, but breaking this cycle by redesigning how information supports the task.

Mapping the fault loops

I mapped the two reinforcing loops that drove faults, and the points where we intervened.

Learning from outside the industry

Research began by looking outside the industry: studying how IKEA and CAD modelling tools handle complex assembly guidance for non-expert users. This surfaced a key insight: the problem wasn't installer capability, it was the information environment. The existing diagrams asked users to remember too much at once.

I mapped the full onsite equipment ecosystem to ensure any solution would scale beyond the spray nozzle, then ran a value/cost prioritisation with the team to focus development on high-impact, low-complexity features first.

An interactive parts diagram system

As a result, I designed an interactive parts diagram system that:

• Aligns digital representation with the physical assembly process
• Breaks down complex assemblies into clear, navigable components
• Links each part to relevant information (identification, ordering, usage)
• Reduces reliance on memory by structuring information progressively

Breaking the cycle

• 95% reduction in equipment faults
• Reduced downtime and operational friction in the field
• Broke the vicious cycle of repeated errors

Designing the right information environment can significantly reduce mistakes without changing the job-to-be-done. — Key takeaway