Virtusa · Aerospace & Manufacturing

Aerospace Digital Transformation

Served as strategic UX consultant and lead designer for the digital transformation of aerospace manufacturing processes — partnering directly with clients from proposal through delivery to redesign enterprise software used on the factory floor.

Role
UX Architect
Designer
Company
Virtusa
Period
2017 – 2019
Team
Lead designer + junior designers
Domain
Aerospace & Manufacturing

The challenge

  • Digitally transform aerospace manufacturing workflows end-to-end
  • Design for high-stakes, low-error-tolerance environments
  • Build scalable design systems for multi-year enterprise engagements
  • Act as strategic UX consultant from proposal through delivery
  • Mentor junior designers across consulting engagements

Aerospace manufacturing operations were being managed through legacy systems that hadn't been updated in over a decade. Factory floor workers and engineers were navigating dense, text-heavy interfaces designed for desktop computers in environments where speed and accuracy were life-safety critical. The disconnect between digital tools and physical manufacturing workflows was creating inefficiencies, errors, and compliance risks.

Understanding the user

Research Artifacts
Journey maps · Personas
Usability sessions · Synthesis

Aerospace manufacturing is a highly specialized domain — I couldn't design for it without deeply understanding it. I conducted extensive on-site contextual research at manufacturing facilities, shadowing engineers and floor workers to understand their actual workflows, decision points, and failure modes. This research revealed that users needed radically simplified interfaces — not because they lacked technical sophistication, but because cognitive load in high-stakes environments needs to be minimized. I also led client stakeholder workshops to map business processes and identify where digital tools were creating the most friction.

Structuring the experience

IA Diagram
Sitemap · User flows
Navigation models

Manufacturing workflows follow strict sequential logic — Step A must happen before Step B, and deviations need to be flagged and documented. I designed an information architecture around workflow state, making it immediately clear to any user where they were in a process, what was required next, and what was blocked. This state-driven IA model became the foundation of the design system and was reused across multiple aerospace client engagements.

How I worked

As UX Architect, I owned the end-to-end design process across multi-year engagements. I started each project with a design sprint to align the client on problem definition before any solutions were proposed. I used rapid interactive prototyping to validate complex workflows early — reducing expensive development rework and accelerating client approval. I mentored junior designers embedded in each engagement, establishing quality standards and design principles that elevated consistency across the portfolio.

01
Discovery & Research
Contextual inquiry, stakeholder interviews, and competitive analysis
02
Synthesis
Journey mapping, affinity clustering, and insight generation
03
Information Architecture
IA modeling, card sorting, and navigation design
04
Design & Iteration
Wireframing, prototyping, and usability testing
05
Delivery & Governance
Handoff, QA, and design system integration

What we delivered

Full-scale UX ecosystems for aerospace enterprise applications — including detailed personas grounded in on-site research, journey maps of manufacturing workflows, complex information architectures, and scalable design systems. Each solution was validated through multiple rounds of on-site user testing with actual factory workers and engineers.

Final Designs
Add screenshots or
Figma embeds here

The impact

Development rework through early prototype validation
3+
Multi-year client engagements delivered
Workflow accuracy in high-stakes environments
1
Reusable design system across multiple aerospace clients
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