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Nexos Operations
Transforming Complex Weld Operations
As the lead UX designer for Nexos Operations, I crafted a modern, role-based platform that streamlines WIP tracking, time logging, and weldāpoint accuracy—reducing training time and errors on the shop floor.
The challenge
Operational needs
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Track WIP with precise weldāpoint data and status transitions.
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Clock-in/out per operator and per operation.
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Surface only relevant actions per role to reduce cognitive load.
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Embed validation to reduce errors and rework.
Constraints
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Industrial environment requiring high contrast and legibility.
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Legacy mental models from paper logs and spreadsheets.
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Limited training time; interfaces must be selfāevident.
The solution
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Led end-to-end UX design from research to implementation
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Conducted stakeholder interviews across all user roles
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Created comprehensive design system and component library
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Designed role-based interfaces with complex workflow management
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Collaborated with development team on technical feasibility
1. Research
Operator interviews, task shadowing, and benchmarking of industrial tools informed the workflow-centric IA.
2. Information Architecture
Status-driven modules mirror real operations: Receiving → In Queue → Prep → Weld → Blend → Rework → Shipped.
3. UX/UI Design
Clean, accessible UI with consistent modals, prominent context (SN, customer, product), and focused action areas.
User Personas & Roles
Production Operator
Manages day-to-day part processing and weld operations
Key Needs
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Quick status updates
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Time tracking
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Clear workflow guidance
Operations Manager
Oversees production metrics and team performance
Key Needs
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Dashboard insights
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Training compliance
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System oversight
Customer
Tracks their parts and views historical data
Key Needs
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Real-time visibility
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Historical reports
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Status transparency
User Feedback
Customer satisfaction and loyalty was measured using Net Promoter Scores (NPS) scores.
Follow up user interviews were conducted.
Key Takeaways:ā
The most frequently utilized features include:
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Viewing claims
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Benefits
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Find a provider
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*Other: locating other information and completing necessary tasks such as submitting forms
The lowest scoring features include:
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Submitting claims
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Managing prescriptions
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*Other: locating other information and completing necessary tasks such as submitting forms
Information architecture
The existing site did not have a site map.
Nailing down and improving upon the current IA was imperative to be able to have a secure site that was flexible but consistent for the many different ways users interact with UMR.
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Personas
The most common user flows were mapped out starting with member personas.
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Flow mapping
The current flows were mapped first as they existed and while looking for ways to improve the architecture and flows moving forward.
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Findings
The design process
Workshops
Identifed use cases
A wide range of use cases were generated based on the personas and what can be inferred from their care needs. (eg. Finding a PCP)
Identifed themes
Use cases were grouped into focus areas (eg. claims, finding cost and care etc) Within each focus area themes were identified; one being benefit clarity.
Consolidated in to features
Based on the identified themes, features were generated to satisfy the use cases.
Site map
Based on the card sorting results, a hierarchical structure was established, outlining the main sections, subcategories, and individual pages.
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A centralized form center was created to make it easy to locate the large number of various forms across different partners and programs. This reduced the average click rate of 5-7+ clicks down to 2 clicks to locate a form.
Content mapping & wireframing
Wireframing out the page based on the content hierarchy to get a sense about layout and gain stakeholder alignment using Figma.
Design system creation
Design and development faced challenges with inconsistent design, inefficient development, and a steep learning curve for new members.
The creation of a comprehensive WCAG compliant design system to be used accross all constituents and white label sites included:
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A Unified Design Language: Defined typography, color palette, and iconography.
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A Component Library: Developed reusable UI components like buttons, forms, and cards.
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Detailed Documentation: Provided clear guidelines and best practices.
High-fidelity mock ups
āResponsive High-Fidelity mock ups were created with rebranding colors so that all the stakeholders could agree on visual direction for hand off to developers.
