Ford

The Bottleneck

Ford's Livonia transmission plant runs components through rigorous testing stages: dynamometer evaluation, calibration, quality checks — all before anything goes into a vehicle. Tracking every part through every step is critical, but the tool workers depended on kept failing them.

Zebra scanners went missing, died mid-shift, and created bottlenecks, while the app meant to replace them was half-built, unreliable, and so poorly conceived it had been named "Songbird." Workers couldn't scan with confidence, couldn't undo mistakes, and had no way to know if their actions had even registered. This isn't just a frustration — it's a quality problem.

New App

A purpose-built iPhone app that lets Ford factory workers scan, track, and process parts without hunting for a Zebra scanner that's dead, missing, or someone else's problem. Ford Scan gives factory workers everything they need to move parts through intake, assembly, calibration, and testing — right from the phone already in their pocket.

Ford Scan is 87.5% more usable than the previous Songbird app it replaced. Ford Scan turns every employee's iPhone into a fully capable factory scanner. A purpose-designed bottom sheet lets workers scan barcodes instantly using the phone's camera — no hardware required. If the camera won't cooperate, they can type the location manually.

Haptic feedback confirms every successful scan so workers know it worked without looking away from the part. The interface follows iOS design standards workers already know, so the learning curve is nearly zero. Clear printer labeling prevents misrouted jobs. A simplified navigation structure means fewer taps to get anything done. And the name — Ford Scan — tells you exactly what it is on the first day and the thousandth.

Being Memorable

“Ford Scan is brilliant.” — The Product Owner. The name and logo change felt like a breath of fresh air — a clear sign that the unfinished app had been replaced with something polished, useful, and genuinely delightful.