iOS Assembly App
A custom iPad application developed for a bike manufacturer's assembly line, designed to streamline operations, enhance efficiency, and reduce assembly times. The app provided real-time work instructions, managed component tracking via barcode scanning, and collected precise timing data at each station to facilitate line re-arrangement and process optimization.
Overview & Background
Problem Statement: The bike manufacturer faced inefficiencies and bottlenecks on their assembly lines, leading to suboptimal production times. Manual tracking of progress and parts was prone to errors, and there was no systematic way to collect granular data on station-specific durations to identify areas for improvement or re-sequence tasks from a linear to a more parallel workflow.
Motivation: To create a robust, mobile solution that digitizes the assembly process, provides real-time guidance to workers, accurately tracks progress and time, and collects critical data needed to scientifically optimize the assembly line layout and task distribution.
Status: This was an internal, client-specific application.
Project Status: Proprietary Client Project
Source Code: Confidential (developed for Potsdam Consulting Advisory GmbH)
My Role
Freelance React Native Developer
Project Duration
10 month
Technical Details
Technologies Used
Challenges & Solutions
Challenge 1
Deployment and Distribution within a Secure Corporate Environment:
Deploying a third-party application onto company-owned Apple tablets within a highly secure business environment, without using public app stores, presented significant hurdles. The client's strict security policies limited direct access and necessitated specific distribution methods.
Solution
Successfully navigated Apple's TestFlight for secure internal distribution and testing. This involved managing multiple build versions, provisioning profiles, and coordinating closely with the client's IT department to meet their stringent security and deployment requirements. The temporary nature of TestFlight builds also required proactive extension management to ensure continuous testing and feedback.
Challenge 2
Real-time Data Integration with Client's Legacy Server:
The app needed to seamlessly communicate with the manufacturer's existing, secure on-premise servers for fetching assembly instructions and uploading time-tracking data. Direct access to the server was restricted due to security protocols.
Solution
Developed a robust API communication layer within the React Native app, strictly adhering to the client's network and security policies. This involved secure data transfer protocols and careful handling of authentication, ensuring reliable and confidential data exchange with their internal server infrastructure.
Challenge 3
Optimizing User Experience for Assembly Line Workers:
The application had to be exceptionally easy to use, even for non-technical users in a fast-paced, potentially noisy environment, minimizing distractions and errors.
Solution
Designed a minimalistic and highly intuitive UI with large, clear buttons and visual indicators. Implemented a straightforward workflow: scan barcode, display parts, strike out completed items. This approach maximized usability, minimized training time, and ensured efficient data collection directly on the assembly line.