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Client
Tata Steel
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Service
UX Design
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Industry
Steel Manufacturing
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Company Size
80,000+
The client
One of India’s and the world’s largest steel producers, operating integrated manufacturing plants across Jharkhand, Odisha, and multiple global locations, had built a bespoke safety incident management platform to govern health and safety compliance across its vast Indian workforce. With over 32,000 employees actively using the system, even marginal usability failures had compounding consequences for incident reporting rates, compliance adherence, and ultimately workplace safety outcomes. Worxwide was brought in to diagnose and redesign the platform’s user experience from the ground up.
The problem
The safety incident management platform was failing its most critical users — frontline workers and supervisors who needed to record, respond to, and review safety events quickly and accurately in high-pressure plant environments across Jharkhand and Odisha. A steep learning curve, cognitive overload, and fragmented workflows were suppressing adoption, reducing reporting quality, and creating compliance risk across one of India’s most safety-critical manufacturing operations.
- Unintuitive Navigation Blocking Platform Adoption — Over 80% of employees found the existing platform difficult to navigate, citing confusing icons, unclear flows, and a non-intuitive information architecture. The steep learning curve was causing under-reporting of incidents and workarounds that compromised safety data integrity across Indian manufacturing sites.
- High Cognitive Load in Critical Safety Workflows — Recording and reviewing safety incidents required navigating multiple disconnected screens with high cognitive demand — a serious design failure for users operating in physically demanding, time-sensitive plant environments across India’s steel manufacturing belt.
- Outdated Forms Limiting Adoption at Scale — Fragmented, legacy-style forms and disconnected workflows frustrated the 32,000+ workforce across diverse roles and locations. The absence of simplified, role-appropriate journeys meant the platform was resisted rather than embraced as a daily safety management tool.
OUR SOLUTION
Worxwide conducted over 100 behavioural user interviews — including recall tests, task flow observations, and empathy mapping — across plant locations in India to identify the precise usability failures driving low adoption and compliance risk. The platform was redesigned around a simplified three-step module structure of Record, Respond, and Review, dramatically reducing cognitive load. System-generated insights and personalised dashboards were introduced to give managers the intelligence they needed, and navigation was rebuilt to feel intuitive to every user level.
- 100+ Behavioural Interviews Across Indian Plant Locations — Deep ethnographic research — including recall tests and task flow shadowing with frontline workers, supervisors, and safety managers across Jharkhand and Odisha — uncovered the specific friction points suppressing adoption and compliance at each manufacturing site.
- 3-Step Record, Respond, Review Architecture — Replacing the fragmented multi-screen flow with a clear three-step structure collapsed the cognitive demand of incident reporting, aligned with how safety professionals naturally think about incidents, and dramatically reduced training time across the Indian plant network.
- Personalised Dashboards and System-Generated Insights — Role-based personalised dashboards gave managers and safety leads real-time visibility without manual data analysis, improving decision-making quality and enabling proactive safety management across each manufacturing persona.
Our work in action
The Impact
80% Reduction in User Friction Across the Platform
Post-launch usability testing confirmed an 80% reduction in reported friction across key incident recording and review workflows, driving higher adoption rates and more consistent compliance behaviour across India’s largest steel manufacturer.
50% Faster Incident Reporting Time
The simplified three-step architecture cut the average time to complete an incident report by 50%, enabling faster response cycles and more accurate, complete safety records across Tata Steel’s Indian manufacturing operations.
Improved Safety Reporting Culture and Platform Adoption
Higher adoption rates contributed to a measurable improvement in safety reporting culture — with more incidents recorded, reviewed, and acted upon, strengthening governance and reinforcing safety as a lived practice across the workforce.
