Design System Overhaul: Cutting Redundant Components and Saving 2–3 Hours per Feature

My Role: Product Manager, Product Designer, Design Operations

Team: 2 Backend Developers, 2 Full-Stack Developers, 1 Software Intern, Junior Graphic Designer, and myself

Duration: 3 Months (June-September 2024)

Built at Exxact Corporation — a B2B high-performance computing hardware company

Context

Fragmented Figma file structure and redundant component library shared across design and engineering at Exxact

Problem

Inconsistent patterns and duplicate components were costing 2–3 hours per feature build and creating design/dev misalignment

Solution

Consolidated the component library into a shared design language with clear naming, usage rules, and handoff documentation

Impact

2–3 hours saved per feature; improved design/engineering alignment and reduced QA rework

Design System Overhaul: Cutting Redundant Components and Saving 2–3 Hours per Feature

My Role: Product Manager, Product Designer, Design Operations

Team: 2 Backend Developers, 2 Full-Stack Developers, 1 Software Intern, Junior Graphic Designer, and myself

Duration: 3 Months (June-September 2024)

Built at Exxact Corporation — a B2B high-performance computing hardware company

Context

Fragmented Figma file structure and redundant component library shared across design and engineering at Exxact

Problem

Inconsistent patterns and duplicate components were costing 2–3 hours per feature build and creating design/dev misalignment

Solution

Consolidated the component library into a shared design language with clear naming, usage rules, and handoff documentation

Impact

2–3 hours saved per feature; improved design/engineering alignment and reduced QA rework

Overview

Overview

As Exxact scaled its product offerings, inconsistencies in design and development slowed teams down. This project focused on creating a single source of truth; reducing fragmentation, improving handoff, and enabling faster, more consistent product development.

The Problem

The Problem

When I joined Exxact, our design process lacked structure and scalability:

When I joined Exxact, our design process lacked structure and scalability:

  • Inconsistent colors, typography, and component behavior

  • Rebuilt components across teams due to poor organization

  • Confusing naming conventions between design and code

  • Difficult onboarding for new team members

  • No clear versioning or ownership of design decisions

  • Inconsistent colors, typography, and component behavior

  • Rebuilt components across teams due to poor organization

  • Confusing naming conventions between design and code

  • Difficult onboarding for new team members

  • No clear versioning or ownership of design decisions

Strategy

Strategy

I led a system-wide effort to standardize design and development workflows:

I led a system-wide effort to standardize design and development workflows:

  1. Audited existing UI assets across platforms

  2. Defined design principles for scalable decision-making

  3. Created a shared taxonomy for design tokens and components

  4. Implemented variables and reusable components

  5. Established documentation, training, and maintenance processes

  1. Audited existing UI assets across platforms

  2. Defined design principles for scalable decision-making

  3. Created a shared taxonomy for design tokens and components

  4. Implemented variables and reusable components

  5. Established documentation, training, and maintenance processes

Audit & Foundation

Audit & Foundation

With a thorough analysis of our existing design ecosystem, I:

Cataloged color usage across platforms, revealing inconsistencies and accessibility issues

Cataloged color usage across platforms, revealing inconsistencies and accessibility issues

Assessed typography scales and hierarchy for alignment and legibility

Assessed typography scales and hierarchy for alignment and legibility

Documented component variations and interaction states to support standardization

Documented component variations and interaction states to support standardization

Partnered with developers to identify and close gaps between design and implementation

Partnered with developers to identify and close gaps between design and implementation

An overview of our ecosystem audit, illustrating the disparate color usage and unstructured component catalog we needed to resolve.

System Architecture

System Architecture

Based on our audit findings, I created a structured design system with:

A foundation layer (colors, typography, grid systems)

A foundation layer (colors, typography, grid systems)

Component libraries organized by function and complexity

Component libraries organized by function and complexity

Clear documentation of usage guidelines and best practices

Clear documentation of usage guidelines and best practices

A walkthrough of the structured design system architecture, designed for intuitive navigation and scalable growth.

Adoption & Training

Adoption & Training

To ensure adoption across teams, I:

Led workshops to align design and engineering teams

Led workshops to align design and engineering teams

Established shared terminology and token structure

Established shared terminology and token structure

Created onboarding resources for new contributors

Created onboarding resources for new contributors

A look at the onboarding resources and shared terminology created to bridge the gap between design and development.

Key Solution 1 - Unified Component Library

Key Solution 1 - Unified Component Library

A centralized library covering typography, color, buttons, forms, navigation, and modals accessible across all projects. I mentored a junior designer throughout, reviewing Auto Layout, variants, and system best practices.

A centralized library covering typography, color, buttons, forms, navigation, and modals accessible across all projects. I mentored a junior designer throughout, reviewing Auto Layout, variants, and system best practices.

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Key Solution 2 - Tokenized Design System

Key Solution 2 - Tokenized Design System

I defined a scalable naming convention using seven attributes (category, concept, property, variant, state, scale, mode), ensuring design and code used the same language.
To support this, I built a Notion tool that automatically generated token names, reducing human error and speeding up implementation.

I defined a scalable naming convention using seven attributes (category, concept, property, variant, state, scale, mode), ensuring design and code used the same language.
To support this, I built a Notion tool that automatically generated token names, reducing human error and speeding up implementation.

Custom Notion tooling in action: Automating the generation and management of our design tokens.

Before and after applying token variables to our buttons.

Notice how much more descriptive they are!

Before and after applying token variables to our buttons. Notice how much more descriptive they are!

The impact of tokenization in code: Standardizing naming conventions to make implementation clearer and more predictable for engineers.

Key Solution 3 - Fluid Responsiveness

Key Solution 3 - Fluid Responsiveness

Introduced CSS clamp() to create fluid typography that scales smoothly across viewports—replacing rigid breakpoints with adaptable sizing.

Storybook demo showcasing responsive h tag sizing.

Key Solution 4 - Change Management

Key Solution 4 - Change Management

Built a Notion-based change log that automatically posts updates to Slack, keeping design and engineering aligned on system updates.

Regular Updates

We plan to integrate documentation upkeep into our quarterly planning, dedicating time for consistent updates.

Regular Updates

We plan to integrate documentation upkeep into our quarterly planning, dedicating time for consistent updates.

Getting Feedback

We'll regularly gather input through forms and user interviews, allowing us to adjust the guidelines based on our users needs.

Getting Feedback

We'll regularly gather input through forms and user interviews, allowing us to adjust the guidelines based on our users needs.

Streamline Maintenance

We're exploring tools and processes to streamline documentation maintenance. We'll engage more with the development team to collaboratively refine and optimize guidelines for lasting usability.

Streamline Maintenance

We're exploring tools and processes to streamline documentation maintenance. We'll engage more with the development team to collaboratively refine and optimize guidelines for lasting usability.

The automated changelog: Tracking detailed token updates to ensure continuous alignment between teams.

Impact - Efficiency & Consistency

Impact - Efficiency & Consistency

Comparing pre- vs post-launch metrics (1 month window):

~3 hrs

~3 hrs

Saved per feature in dev

Saved per feature in dev

~2 hrs

~2 hrs

Saved per screen in design

Saved per screen in design

~3 hrs

~3 hrs

Saved per PR/design review

Saved per PR/design review

40

40

Duplicate components removed

Duplicate components removed

20%

20%

Color token reduction (54 → 43)

Color token reduction (54 → 43)

30%

30%

Text styles reduction (20 → 14)

Text styles reduction (20 → 14)

Project Reflection Metrics

Project Reflection Metrics

A quick look at how this project felt—measured by challenge, teamwork, and personal sanity.

What I Learned

What I Learned

Impact

A Single Source of Truth

Creating a shared design system transformed how we build products, reduce design time, improving consistency, and laying a scalable foundation for future growth.

Technical Challenge

Learning Through Complexity

This was one of the most technically demanding projects I’ve worked on. With no formal mentor, I relied on deep research, experimentation, and iteration to navigate unfamiliar design system concepts.

Collaboration

Raising the Bar Together

Despite the challenge, the project significantly strengthened cross-functional collaboration. Close partnership with engineering helped us align on decisions and establish stronger design standards.

Iteration

Trial, Error, and Progress

The implementation required ongoing refinement. Through trial and error—and constant feedback from a small but engaged team—we steadily improved both the system and our process.

Shared Language

Debate That Builds Better Systems

Lively discussions with the software team, especially around token naming, pushed us toward clearer, more durable decisions. These conversations ultimately made the system stronger.

Looking Ahead

Built to Evolve

With a solid foundation in place, the next step is expanding the system to support themes and dark mode—leveraging the variables and structure we’ve already defined.

DESIGNED BY KATHERINE CHHAY CHEN
®2026
DESIGNED BY KATHERINE CHHAY CHEN
®2026