Read time: 3 - 5 minutes
Timeline
Team
Tools Used
Deliverables
Results
The Challenge
Technicians were relying on manual checks, inconsistent logs, and trial‑and‑error to diagnose flame sensor faults. Critical signals were buried in hardware readouts, and troubleshooting steps varied widely across teams. This led to longer downtime, inconsistent repairs, and limited visibility into sensor health during high‑risk industrial operations.
MY ROLE
THE APPROACH
Partnered with engineering, product, and field technicians to translate complex hardware behavior into a clear, reliable diagnostic experience that reduced downtime and improved repair accuracy.
• Faster fault detection with real‑time sensor feedback
• Clearer workflows from visual fault states
• Less downtime through guided, hardware‑mirrored UI
STEP 1
Observed technician workflows, reviewed hardware logs, and mapped the end‑to‑end diagnostic process to identify friction and failure points.
Collaborated with firmware engineers to translate raw sensor data into readable states, thresholds, and health indicators.
STEP 2
STEP 3
Designed structured troubleshooting paths that surfaced root causes, recommended actions, and real‑time sensor feedback.
Created a clean, industrial‑safe interface with clear hierarchy, color‑coded states, and guided steps aligned to technician behavior.
STEP 4
STEP 5
Tested UI behavior against live hardware signals using engineering test rigs to validate timing, accuracy, and state transitions.
Delivered specs, collaborated with engineering during integration, and refined interactions based on real‑world test feedback.
STEP 6
Metrics
50% faster fault identification during field diagnostics
Reduced technician guesswork through guided troubleshooting flows
Clear visibility into sensor health, thresholds, and failure modes
Improved engineering confidence through accurate, real‑time signal mapping
Diagnostic patterns reused across additional hardware tools, reducing future design efforts
Conclusion
The diagnostic tool replaced a manual, error‑prone workflow with a clear, real‑time interface that aligned hardware signals with technician behavior. By surfacing sensor health, fault states, and guided troubleshooting steps, the system reduced downtime, improved repair consistency, and established a scalable diagnostic framework for future Chentronics hardware products.
DELIVERABLES
Technician Workflows
Sensor Configuration
Visual Identity
Data Visualization
Wireframes
Data Visualization
Final Designs
Final Designs
Final Designs
Prototype
