Hussey Seating asked Tool to reimagine their Service Light, a small indicator mounted on bleacher skirt panels that signals when annual inspection is due. The original version relied on a PLC box and runtime tracking, making it too complex and too costly. Customers rarely used the advanced functions, which meant many banks of bleachers went without lights—undermining the goal of consistent safety checks. Hussey’s objective was clear: create a far more affordable, battery-powered unit that could be installed on every bleacher, powered or manual, and reset easily by a technician after service.

Tool’s approach focused on stripping the design back to essentials. We studied installation practices, retrofit challenges, and user interaction to define a self-contained module that mounts directly on skirt panels with minimal drilling or fasteners. Industrial design emphasized a durable, high-value look that fit Hussey’s brand while keeping parts and assembly costs low. Engineering introduced a simple timer-based trigger and intuitive reset, supported by compact PCB design and firmware tuned for cost and long battery life. Prototyping was staged to validate layout, durability, and ease of use, before TOOL executed on vendor sourcing, tooling and production.

The result was a rugged, simplified service reminder—practical to install across new and existing bleacher systems, inexpensive enough to standardize on every bank, and straightforward for technicians to maintain. By focusing on usability and cost reduction, the redesigned Service Light positioned Hussey to expand adoption, improve safety compliance, and deliver more value to facility owners.