Process Digitization

Six Sigma Compliance Tracker

A purpose-built platform that moved Granules India's Six Sigma Green Belt program from paper forms and spreadsheets into a guided DMAIC digital execution environment.

🏢 Emphatic Sense Technologies2023

🔒 Source & live demo not available — built under NDA

About the Project

Granules India's Six Sigma program ran on a combination of paper forms, spreadsheets, and process knowledge held by individual practitioners. This project replaced that with a structured web application where Green Belt practitioners work through Define (7 deliverables), Measure (12), Analyze (11), Improve (6), and Control (14) phases — with file attachments, metrics tracking, and phase completion tracking across 4 backend microservices.

The initial design planned specialized input forms for each Six Sigma tool — structured screens for Fishbone Diagrams, FMEA tables, Cause-Effect Matrices. Early feedback revealed that practitioners create these artifacts in their own tools (Excel, Minitab, PowerPoint) and needed a system to track and verify completion, not to build artifacts from scratch. The approach pivoted to a config-driven generic deliverable system (file upload + remarks per deliverable) — fitting the app's role as a compliance tracker rather than an authoring tool. The architecture still supports adding specialized forms per deliverable ID if needed.

A nested tab system with URL search param state management lets practitioners deep-link into any phase, deliverable, or form without losing context.

Core Concepts

🔬

DMAIC Phase Guidance

Each phase — Define, Measure, Analyze, Improve, Control — has dedicated deliverable forms, attachment uploads, and metrics tracking screens that enforce structured Six Sigma methodology across 50 configurable deliverables.

📂

URL-Driven Nested Navigation

Multi-level tab system with state encoded in URL search params (activeTab, activePhase, activeFormId), enabling deep linking into any deliverable and preserving full navigation context on refresh or share.

📊

Metrics Visualization

Recharts-powered grouped bar charts render monthly target, actual, and projected metrics within each DMAIC phase, with editable data tables that sync with the visualization in real time.

Key Challenges & Solutions

Challenge: Navigating Deep Workflow Hierarchy

DMAIC phases contain sub-phases, each with multiple deliverable forms — a flat navigation structure couldn't represent the depth without overwhelming practitioners.

✓Solution: Designed a nested tab system with URL search param state via a custom useSetSearchParams hook, preserving each level's context on navigation, refresh, and deep linking into any specific deliverable form.

Challenge: Specialized Forms vs. User Adoption

The initial approach planned unique, tool-specific forms for each Six Sigma deliverable — structured inputs for Fishbone Diagrams, Cause-Effect Matrices, FMEA tables, and so on. Early feedback indicated practitioners preferred flexible uploads over rigid form structures, making specialized forms unnecessary.

✓Solution: Pivoted to a config-driven generic deliverable system — each deliverable became a standardized attachment form (file upload + remarks) managed through a single LoadDeliverables component that routes by form ID. This traded domain-specific depth for user adoption and flexibility, while the architecture (formConfig maps, phase-keyed routing, Zod-validated schemas) still supports adding specialized forms per deliverable if needed later.

Challenge: Consistent Data Synchronization Across Table, API, and Chart

Each DMAIC phase has a metrics tracker where users define metrics, enter monthly values in an editable table, and need to see grouped bar chart visualization update as data changes — with save, update, and validation across the full flow.

✓Solution: Built a coordinated system using RTK Query mutations for save/update, Zod schemas for data validation, and a Recharts GroupedBarChart that re-renders from the same data the table edits — with RTK Query cache invalidation ensuring the chart always reflects the latest saved state.

Tech Stack

Frontend

ReactTypeScriptViteTailwindCSSShadcnUI

State & Data

Redux ToolkitRTK QueryReact Hook FormZod

Visualization

Recharts

Other

i18nextPWAsecure-ls

Impact Metrics

DMAIC Deliverables

Microservices Integrated

5-phase

DMAIC Coverage

My Role

Title

Systems Engineer

Duration

2023 – 2024

Key Responsibilities

DMAIC phase screens with 50 configurable deliverables across Define, Measure, Analyze, Improve, and Control
URL-driven nested tab navigation system with deep linking into any phase and deliverable
Recharts grouped bar charts for per-phase metrics visualization with editable data table sync
Zod schema validation for form inputs and API response verification

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