Schneider Electric Case Study

IoT Innovation Transforms Energy Hardware Supply & Assembly

Schneider's electrical panels in ascending stages of assembly.

The Opportunity Disrupt the Switchboard Market by Slashing Production Lead Times

Schneider Electric is a global leader in energy management, driving innovation and sustainability. Focused on digital transformation, they help businesses and homes optimize energy efficiency and reduce carbon emissions with intelligent solutions. Schneider Electric aims to shape a greener, more resilient future, making energy safe, reliable, and accessible for all.

Schneider faced a significant challenge in their commercial building sector, where the processes for supplying, assembling, and certifying electrical panels were lengthy and inefficient. Contractors often experienced delays in receiving necessary parts, followed by further wait times for an auditor to inspect and approve the assembled panels. This process could take several weeks, considerably slowing construction project timelines.

To address this issue without compromising quality, Schneider Electric set out to streamline the process and dramatically reduce assembly and certification times. Their objective was to enable contractors to assemble panels on-site, provide real-time compliance verification, meet the growing demand for shorter construction lead times, and minimize delays in switchboard availability.

Our Response Engineering an Innovative IoT Assembly and Compliance Application

Schneider Electric partnered with MojoTech to design and develop a comprehensive, mobile-first app to streamline the assembly and certification of electrical panels. The solution needed to empower contractors to configure, assemble, and validate custom electrical panels directly at job sites using iPads while ensuring adherence to Schneider Electric's rigorous standards.

Schneider Electric FlexSet assembly assistance and compliance mobile app interface.

Product Discovery and Strategy

MojoTech initiated the project by launching a product discovery and strategy phase, which included a journey-mapping workshop with a cross-functional Schneider Electric team. Together, they mapped out essential journeys for three personas: the Assembly Operator, Production Supervisor, and QC Inspector. The workshop documented each step of their processes, identifying pain points and positive experiences throughout the switchboard assembly and validation stages.

These journey maps became the foundation for defining essential use cases, workflows, and product features. They guided the development of user flows, information architecture, and wireframes. By focusing on one or two critical tasks at each step, the team was able to prioritize the most impactful work for each persona, ensuring product development aligned with Schneider's specific needs.

Assembly Assistance with Quality Control

Schneider Electric's existing assembly app supports safe and accurate switchboard assembly by guiding workers through the process based on individual orders. Each order is divided into line items representing modular kits with components that specify the required tools, parts, and verification steps.

MojoTech enhanced this system by adding a step-by-step guide that allows contractors to scan hardware components using QR codes. This ensures all parts are correctly tracked and helps users assemble the switchboard according to exact specifications, reducing errors and minimizing rework.

To support this enhancement, we received spreadsheets with detailed instructions and developed an import tool that seamlessly integrates these steps into the app. The instructions vary based on the specific breakers and components in each order. Our solution simplified the creation of these step-by-step guides, implemented QR code tracking for components, and laid the foundation for a fully automated assembly system.

Bluetooth-Enabled Torque Wrench IoT Integration

A standout feature of this app is its seamless integration with a Bluetooth torque wrench. Working from a curated shortlist by Schneider Electric, MojoTech identified the optimal wrench to meet the app's technical specifications. We then incorporated it into the platform to provide real-time feedback during assembly. The wrench emits an audible alert when the correct torque for each component is achieved, ensuring every screw and bolt is tightened to precise standards. This IoT app ensures compliance with Schneider Electric’s strict safety and performance requirements, enhancing accuracy and efficiency.

Quality Assurance Workflows

The app caters to two primary user groups: Assembly Technicians and Inspectors. After assembly is completed, inspectors are prompted to verify each step, ensuring that all components, such as screws and breakers, are correctly installed, leaving nothing overlooked. Photos of the completed panels are captured for documentation, creating a transparent and auditable data trail.

Key stakeholders, including Schneider Electric, UL, government electrical inspectors, and contractors, will have access to analytics and detailed metadata, such as where and when the switchboard was assembled, who completed it, and other relevant information.

UL Compliance and Certification

Schneider switchboards are UL-certified, a mark of safety recognized worldwide and trusted by government organizations. Since Schneider manufactures its own switchboards, it maintains complete control over the assembly process. This oversight ensures compliance with UL standards, allowing Schneider to directly label its switchboards with the UL certification, reflecting their commitment to safety and quality.

The app ensures that every panel meets UL certification requirements by integrating checks throughout the assembly process. Once assembly is complete, the app allows users to generate and print UL certification labels, simplifying the final certification step.

The Results IoT App Development Streamlines Operations, Accelerates Delivery, and Elevates Quality Control

The Assembly and Compliance app allowed Schneider Electric to eliminate bottlenecks, allowing contractors to self-assemble panels, ensure compliance, and complete projects faster. This innovation streamlined operations and positioned Schneider Electric as a leader in reducing lead times and improving quality control in the electrical panel industry. Some other key benefits include:

Speed to Market

The app shortens lead times for electrical panels by eliminating contractors needing to wait on auditors or assembly experts, streamlining project timelines.

Improved Quality Control

With the integration of Bluetooth wrench technology, Schneider Electric could monitor each step of the assembly process in real time, ensuring all panels met high standards.

User Empowerment

Contractors and inspectors were equipped with tools to manage panel assembly efficiently, reducing reliance on external resources and enhancing the overall user experience.

Flexible & Scalable

The app's ability to edit assembly instructions and integrate new QR-coded components makes it future-proof, enabling Schneider Electric to add automation features and scale the solution.

“Our experience with MojoTech is outstanding. Their team displays unparalleled flexibility and supports our projects from start to finish, with exceptional attention to detail. Their dedication to delivering the best possible outcome for their clients is truly commendable. We highly recommend MojoTech to anyone looking for top talent, quality output, and a team that's easy to work with.”

Jason Lien

Director of Product, Schneider Electric