An SPC implementation focused on compliance and client satisfaction

Green Garden Food Products, Inc., a manufacturer of gourmet salad dressings, sauces and marinades, has implemented Zontec's Synergy 1000™ Statistical Process Control (SPC) Software within its Quality Assurance Lab to systematize their record keeping and to replace an older, under performing system.

Beyond their own Green Garden-branded product lines, the company is heavily involved in co-packing for large-volume clients who demand strict processing procedures and consistent levels of quality. The Synergy 1000 software has been an extremely effective tool for communicating and satisfying acceptability levels with these clients.

The software records, monitors and reports such quality characteristics as pH concentration, titratable acidity, titratable salt, viscosity, product and equipment temperatures, fill weights and torque on jar lids, depending on each client's unique requirements. As a co-packer, Green Garden must match precisely what the client has already achieved in its own R&D labs, a pilot plant for new products or other manufacturing facility.

On-the-fly trouble-shooting

Green Garden uses Synergy 1000 to its advantage as a rapid communication, feedback, and problem-solving system for their clients. "We're able to exchange information very easily," says Roth Gonzales, Quality Assurance Manager. "I can quickly document their requirements with Ppk, Cpk numbers, capability charts and control charts. They, in turn, respond with changes or recommendations while we're manufacturing their product," he explains.

One client, who also uses Zontec SPC software, receives data from Gonzales over the Internet, and supplements Green Garden's tests with their own reports and analyses.

"It's really helpful, especially for new products, after the first couple of production runs to see our upper and lower limits, the spec ranges, the capability of our machines in our Mixing Operations and what sort of targets we should be shooting for," he continues.

The Synergy 1000 charts and graphs are also a valuable tool that Gonzales uses internally during weekly management meetings to visually convey what's happening with the process instead of just presenting raw data to the staff. Using fill weights as an example, he points out: "It's simple to prove if we're running a bit high; it opens the door for discussions about how to lower it and improve our profitability."

Totally integrated SPC

"Previously, if I wanted to do any reporting or analysis, I would have to import the data into Excel, get involved with the statistical calculations, and create my own charts which were pretty basic bell curves and run charts. Now data collection, charting, analysis and reports are all integrated into the system. I just select the data and create the corresponding chart. Synergy 1000 represents about a 50% jump forward in our ability to manage and report the data," he notes.