QTrack — EV Quality Management System
Vardhanika Jagtap
QTrack — EV Quality Management System
Before an electric vehicle reaches the customer, it passes through dozens of quality inspections across the manufacturing line. I designed QTrack to replace fragmented paper-based inspections with a connected digital ecosystem that enables Makers, Quality Gate inspectors, and supervisors to collaborate seamlessly while improving traceability, speed, and production quality.
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Role
End-to-End Product Designer
Timeline
2025 | 12 Weeks
Client
Leading Electric Vehicle Manufacturer
Tools
Problem Statement
Paper Couldn't Keep Up
Every electric vehicle moving through production must pass multiple quality gates before it can leave the factory.
At every stage, Makers complete assembly tasks while Quality Gate inspectors verify that every component meets manufacturing standards.
Despite producing thousands of inspections every month, the entire workflow relied on handwritten checklists, printed documents, and manual communication.
Supervisors couldn't instantly identify production bottlenecks.
Inspectors repeatedly documented the same defects.
Workers depended on physical paperwork moving alongside every vehicle.
Questions
Has this vehicle completed every quality check?
Which defects are still unresolved?
What feedback did the Quality Gate inspector leave?
Which station is currently holding production?
Has this vehicle already been re-inspected?
The opportunity wasn't creating another enterprise dashboard. It was transforming quality management into a connected workflow that reduced paperwork while keeping production moving.
Activities
Factory Workflow Study
Contextual Research
User Interviews
Process Mapping
Information Architecture
Kiosk Experience Design
Admin Dashboard Design
Design System
High Fidelity Prototyping
0%
of inspection activities followed repetitive paper workflows.
0
connected user roles across production.
0
devices designed for completely different environments.
0
manual paper dependency after digitisation.
Defining Problem Statement
Workers weren't asking for modern software. They wanted a faster way to complete inspections without learning complicated interfaces. Instead of redesigning how factories operate, I redesigned how inspection information flows between people, creating a digital experience that feels as straightforward as the paper process it replaces.
Research
Understanding the Floor
Rather than beginning with interface design, I first mapped how inspections actually moved through the factory from Makers completing work, to Quality Gate inspectors reviewing vehicles, to supervisors tracking production quality.
This helped reveal where delays, miscommunication, and repetitive manual work occurred.
Ramesh
42 • Quality Gate Inspector • Nashik
"My job isn't finding problems. It's making sure they never leave the factory."
Pain Points:
Repeating handwritten observations
Searching through previous inspection sheets
Difficult to track unresolved issues
Paperwork slows inspection speed
Mahesh
31 • Maker • Nashik
"Tell me what's left. I'll fix it immediately."
Pain Points:
Feedback isn't always clear
Waiting for paperwork
No visibility of pending defects
Difficult to track approvals
Priya
38 • Production Supervisor • Nashik
"By the time reports reach me, production has already moved on."
Pain Points:
Manual reporting
Limited production visibility
Delayed defect trends
Difficult quality analytics
Vikram
46 • Production Line Manager • Nashik
"I don't need to inspect every vehicle, I need to know where production is slowing down."
Pain Points:
No real-time visibility into inspection progress
Delayed updates due to paper-based reporting
Difficult to identify recurring bottlenecks
Time-consuming coordination between multiple teams
Key Insight
Factory workers don't need feature-rich software.
They need immediate confidence that every inspection is complete before the vehicle moves forward.
Opportunity mapping
Finding the Friction
After understanding how inspections moved across the production line, I mapped every step of the workflow to identify where digital interactions could create the greatest impact.
Instead of digitising every paper form, I focused on reducing repetitive work, improving communication, and making quality information immediately accessible to the people who needed it.
Every feature was prioritised based on two criteria:
• Operational Frequency — How often workers perform the task during production.
• Production Impact — How much the task affects vehicle movement, quality assurance, and overall manufacturing efficiency.
Rather than building a feature-heavy system, QTrack focuses on removing friction from the moments that happen hundreds of times every day.
Digital Inspection Checklist
Defect Feedback Loop
Vehicle Search
Live Inspection Status
Inspection History
Role-based Access
Real-time Reports
Checklist Configuration
Production Analytics
Information architecture
One Workflow. Two Platforms.
QTrack isn't a single application.
It's a connected ecosystem where each user only sees the tools required for their responsibilities.
Separating operational tasks from administrative controls keeps the interface focused while ensuring every inspection remains connected through a shared source of truth.
The kiosk supports production-floor activities, while the desktop dashboard provides configuration, reporting, and operational oversight.
Design Principles
Designed for the Floor
Designing for a manufacturing environment meant prioritising usability over visual complexity.
The primary users weren't technology experts they were skilled workers focused on assembling and inspecting vehicles under time-sensitive conditions.
Every design decision aimed to minimise cognitive effort while supporting fast, accurate interactions.
Recognition over Recall
Workers shouldn't memorise inspection sequences. The interface guides users step by step using familiar terminology, clear progress indicators, and contextual actions.
Large Touch Targets
Shared kiosk devices are used throughout the day, often while workers wear gloves. Buttons, checklist items, and navigation were designed with generous spacing to reduce touch errors.
Minimal Typing
Typing slows production. Most interactions rely on selections, toggles, predefined defect categories, QR scanning, and simple confirmations instead of manual text entry.
Clear Status Visibility
Every vehicle immediately communicates its inspection state. Approved, Pending, Failed, and Rework statuses are visually distinguishable so workers can understand progress at a glance.
Familiar Workflow
Rather than forcing workers to learn an entirely new process, the digital experience mirrors the existing paper workflow while eliminating repetitive manual tasks.
Design system
Designed to Scale
With multiple user roles, two platforms, and hundreds of inspection screens, consistency became essential.
A shared design system ensured that every interaction from checklists and feedback cards to status indicators and reports felt familiar regardless of where users entered the workflow.
The system was designed around clarity, scalability, and accessibility, enabling future inspection modules to be added without redesigning the experience.
The Final Experience
From Inspection to Insight
Login - Kiosk
Vehicle List - Kiosk
Checklist - Kiosk
Visual Inspection - Kiosk
History Card - Admin
Impact Overview
Turning paperwork into production intelligence.
Digitised the inspection process
Replaced paper-based quality inspections with a connected digital workflow, allowing every inspection to be captured, tracked, and reviewed in one system.
Improved collaboration
Created a structured feedback loop between Makers and Quality Gate inspectors, reducing miscommunication and making issue resolution more transparent.
Increased operational visibility
Enabled supervisors to monitor production status, inspection progress, and quality performance without waiting for manual reports.
Reduced manual effort
Automated inspection records, reporting, and historical tracking, eliminating repetitive paperwork and improving traceability.
Built for scale
Designed a flexible quality management platform capable of supporting additional production lines, inspection templates, and manufacturing processes as operations grow.
Explore the complete prototype to see how Makers, Quality Gate inspectors, and supervisors collaborate through a connected quality management workflow.
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Posted Jul 28, 2026
Digitised EV inspection workflows with QTrack, connecting kiosks and admin dashboards to reduce paperwork and surface production intelligence.
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