02CASE STUDY
NEXUS CONTROL SYSTEM.
A unified control platform that brings precision, visibility, and autonomy to complex industrial operations.
- CLIENT
- Vortech Industries
- INDUSTRY
- Advanced Manufacturing
- YEAR
- 2024
- SERVICE
- Product Design / UI/UX + Systems
01OVERVIEW
CHALLENGE
Operators ran production lines from five legacy consoles with conflicting alarms, inconsistent units, and no shared view of system state.
APPROACH
We mapped every operator decision, then designed one control surface around them: a single state model, ranked alerts, and a component system that scales from a wall display to a handheld.
OUTCOME
One platform now runs every line. Operators reach decisions faster, alerts are trusted again, and new screens ship from the system instead of from scratch.
02KEY METRICS
RESPONSE TIME-38%VS LEGACY CONSOLES
TIME TO DECISION4.2sMEDIAN, OPERATOR TRIALS
UPTIME99.98%FIRST 90 DAYS
OPERATOR ERRORS-61%INCIDENT REVIEW
03PROCESS
12 WEEKS- DISCOVER1 WEEK
- DEFINE2 WEEKS
- DESIGN3 WEEKS
- BUILD3 WEEKS
- TEST2 WEEKS
- REFINE1 WEEK
04DELIVERABLES
- 01Control interface system
- 02Alert and escalation model
- 03Component library
- 04Data visualization kit
- 05Motion guidelines
- 06Operator onboarding flow
- 07Design token pipeline
05VISUAL SYSTEM
- 01
STATE MODEL
One source of truth for every line.
- 02
ALERT HIERARCHY
Ranked by urgency, not by source.
- 03
SYSTEM OVERVIEW
Plant-wide status at a glance.
- 04
TELEMETRY
Live signals with stable scales.