1. Stoplight Color Coding

Synergy SPC software allows users various ways to proactively monitor the production process.

Synergy software incorporates stoplight color coded status indicators and charts to allow users to immediately determine the state of a process. Control status indicators and variable charts identify if the process is in control (green), trending towards being out-of-control (yellow), or out-of-control (red). Specification status indicators and run charts identify if measurements are good (green), trending towards out-of-specification (yellow), or out-of-specification (red).

“We are daily able to monitor critical characteristics in an effective, real-time, proactive, manner and predict if the processes or the tools are trending towards going out-of-control,” said Aditya Deshpande, Quality Assurance Manager for Cumberland Plastics Solutions.

“Now that we have the analysis in a user friendly format, we are using Synergy as our communication tool. By viewing a capability chart, everyone can immediately tell how things are going,“ remarked April Lusk, Director of Quality for Trident Precision Manufacturing.

“We can take preventative action versus being reactive. With the data from Synergy, everyone; from the operator, to the manager, to the engineer, can monitor an issue and resolve the issue before it adversely affects our customers,” commented Heidi Beaver, Quality Technician for Portage Plastics Corporation.

2. Notifications of Trend Test Violations

Synergy software allows users to select which trend tests they want applied to each characteristic. When a trend test is violated, the user receives immediate notification including the specific trend test that was violated. If the automatic email notification is enabled for out-of-control (OOC), defined recipients will also receive an email as soon as the data is entered.

“We also estimate we are saving approximately 30% of an operator’s day due to data entry. Using Synergy 2000 we have eliminated data entry errors. We are able to measure a part completely and save 30% of our time doing it,” noted Ted Black, QA Manager for the A.P. Plasman-Windsor Plant.

3. Automatic Emails for Out-of-Control and/or Out-of-Specification

Synergy software enables you to setup notifications to the appropriate personnel if a process or processes are out-of-control, out-of-specification or both.

“With Synergy we could capture more data about our business. Email alerts for out-of-specification products were part of the deciding factor for selecting Synergy,” said Kim Marquis, Operations Manager for Polymerics.

“Using Synergy is a lot more user friendly, because you can run SPC in real-time. Now if anything goes out-of-specification, I get an email notification at my desk instead of having to physically be on the shop floor. In the past, we wouldn’t know if we were trending or not. Implementing Synergy saves us about 2 man-hours a day.” Brian Brooks, VP of Operations for Domestic Fastener & Forge, Inc. (DFFI).

In order to reduce scrap, rework and downtime, you need SPC software that allows all levels of users to be proactive and take corrective action at their position of the production process.

Synergy 3000 Web Manager Box & Whisker Plot.

Zontec has a new eBook that articulates what companies should expect from their Statistical Process Control (SPC) Software vendor. It encompasses the following prerequisites that are vital for the smooth integration of SPC Software into your environment:

• A Product Tailored for Your Business
• Easy to Setup so You can Realize a Rapid Return on Investment (ROI)
• Seamlessly Integrates Into Your Production Environment
• Delivers Extensive Reporting for All Users
• Meets Unique Regulatory and Customer Requirements
• Reduces Downtime, Scrap Rate, and Rework
• Ensures Production of High Quality Products
• Enables Customers to Develop New Products
• Provides a Global View of Your Entire Supply Chain
• SPC Software Company That Continuously Innovates Its Product Line
• Software Company That Provides Personalized Support
• SPC Company with a Proven Track Record

“Implementing Synergy has helped us to reduce scrap, reduce rework, reduce costs, and ensure that we deliver our products on-time to our customers,” said Dave Ibanez, Vice President of EC Operations at Veridiam.

To learn more about how the Synergy SPC Software Product Suite meets these requirements. Click on Benefits of Synergy Software or the green button on the right.

Each chart in Synergy SPC software allows users to change numerous options instantly.

Time is money. Increases in personnel productivity can be a big cost savings. Synergy software enables you to automatically collect data and gives your operators real-time feedback so they can make adjustments instantly. Your operators are freed-up from paperwork, able to ensure that their data is error-free, prevent out-of-control conditions before they occur, and focus on their production jobs. Managers simultaneously monitor multiple processes at facilities and supplier locations globally. Your engineers instantly analyze the data, suggest process improvements based on historical data, prevent out-of-control or out-of-specification conditions from occurring, monitor production equipment and provide statistical process control (SPC) software data and analysis to management, customers or regulators in the specified format

Here are some Zontec customers who have experienced significant time savings with Synergy:

• “What used to take a couple of days of work a week before using Synergy, now takes a push of a button. Now we have real-time information as we are weighing the bags,” said Glen Peters, Lab Technician for Polymerics.

• “Synergy saves us about 45 minutes of the operators’ time from how we operated previously. When you calculate this across 22 machines that comes out to about 33 man-hours a day,” noted Scott Chambers, Quality Facilitator for Schoeneck Containers Inc.

• “We’re running 2 shifts with 2 quality people. It used to take 3 quality people. Implementing Synergy is saving us 14 hours a day,” said Wayne Maurer, Quality Manager for MET Plastics.

• “As Quality Manager, what used to take a day’s worth of work to determine our Cpk’s and our Ppk’s is now just a click of a mouse. Now I have a tool that enables me to analyze, report, and explain in an efficient manner the current state of our processes. I have the data to show where we can improve our processes,” commented Aditya Deshpande, Quality Assurance Manager for Cumberland Plastics Solutions.

• “We also estimate we are saving approximately 30% of an operator’s day due to data entry. Using Synergy 2000 we have eliminated data entry errors. We are able to measure that a part completely and save 30% of our time doing it,” remarked said Ted Black, QA Manager for the A.P. Plasman-Windsor Plant.

• “Since implementing Synergy, the reduction in paperwork is huge. Before every entry took us about 3-½ minutes per sample size and now it only takes us less than 30 seconds. There are 240 critical characteristics we could be measuring at any given time. Using Synergy has saved us about 12 man-hours per day,” said Douglas Winfrey, Director of Quality for United Gear and Assembly.

Increased personnel productivity alone can justify investing in Synergy software. Choose from our product suite for the software package that fits your business.

Reduce Scrap Rate

• “The software has served as a great training program for our employees. Synergy has helped us in process improvement: we have seen a scrap reduction of 2%,” said April Lusk, Director of Quality for Trident Precision Manufacturing.
• “Since using Synergy 3000, we have reduced our scrap rate by 20%,” commented Fedele D’Alessandro, General Manager for LMPsrl.
• “The Synergy 2000 software has also enabled us to reduce waste. We have reduced our scrap rate by 2%,” said Cary Williams, Process Leader for Amantea LLC.

Reduce Rework

• “The other way we are saving money is the fact that we have decreased considerably the amount of rework we are performing. Now we have the visibility to see when a process is trending towards going out of control. We can make adjustments so it doesn’t go out-of-control—saving us a tremendous amount of repackaging,” said Tim Stutzman, Manufacturing Systems Analyst for Oregon Freeze Dry.
• “Using Synergy 1000 is a lot more user friendly, because you can run SPC in real-time. Now if anything goes out-of-specification, I get an email notification at my desk instead of having to physically be on the shop floor. In the past, we wouldn’t know if we were trending or not,” said Brian Brooks, VP of Operations for Domestic Fastener & Forge, Inc. (DFFI).

Reduce Downtime

• “With Synergy 1000, We are able to monitor critical characteristics daily in an effective, real-time, proactive, manner and predict if the processes or the tools are trending towards going out-of-control,” said Aditya Deshpande, Quality Assurance Manager for Cumberland Plastics Solutions.
• “Synergy 3000 provides us visibility into our processes so that we have improved control and can be proactive vs. reactive to issues,” said Don Bartlett, Director Quality & Customer Service for Grakon LLC.
• “If the data shows that a particular machine is trending towards being out-of-control, we take corrective action. We are now able to ensure that our production process meets our daily goals and delivers a quality product. Using Synergy 2000 has helped us increase our uptime by 10 to 15%,” said Cary Williams, Process Leader for Amantea LLC.

Synergy Customizable Standard Report Displaying 4 Charts.

Although Statistical Process Control (SPC) software involves many complex calculations to ensure that your processes are in control and within your customers’ specifications, implementing SPC software does not need to be a long complicated process. “The reason we selected Synergy was because file creation literally takes minutes,” said Chris Gauthier, Quality Manager for Multicircuits. “The fastest thing I’ve ever done was to set up 60 tables in 2 days,” commented Bob Hyland, Process Engineer for Acme Aerospace.

Myth #2: SPC Software is Difficult to Use and Understand

SPC software should require minimal training and be easy-to-use. “We have found the software to be easy-to-use and straightforward. Using Synergy, we are easily able to train our junior operators who do not have any SPC experience,” said Fedele D’Alessandro, General Manager for LMPsrl.

Myth #3: SPC Software is Not Conducive to Varying Production Environments

“We needed the ability to adapt on the fly for different run sizes. For us, Synergy is just simpler. Because we have short runs, being able to track it and tell me when something is trending out-of-control or out-of-specification is important, during those few hours. It also gives me the ability to compare previous runs,” said Wayne Maurer, Quality Manager for MET Plastics. Because every production environment is different, SPC software can accommodate production environments of any size on a local or global scale. “We run 5 packaging lines a day with products running in the thousands. If we can reduce our range by a gram, that saves us a ton of money. Without Synergy, we would not be able to set such tight tolerances,” said Tim Stutzman, Manufacturing Systems Analyst for Oregon Freeze Dry.

Myth #4: SPC Software Only Affects the Quality Department

SPC Software data benefits the entire company. Data collection and analysis begins with your suppliers and is continuously monitored until shipped to your customers. “Now that we have the analysis in a user-friendly format, we are using Synergy as our communication tool. By viewing a capability chart, everyone can immediately tell how things are going, “ said April Lusk, Director of Quality for Trident Precision Manufacturing.”Synergy software gave the definitive objective measurements, in real-time, to improve quality and communication with our suppliers,” said Dan Heimann Quality Manager for MASS Precision. “Sometimes we are asked to send materials directly to the ship yards. These are usually orders with a fast turnaround. Because the data is readily available, we can provide all the documentation quickly along with the products we are shipping out,” said Bob Batsche, Quality Manager for Carlisle & Finch Co.

Myth #5: SPC Software Does Not Provide a Rapid Return on Investment (ROI)

Elegant SPC software can be easily implemented and operators can promptly begin improving processes. Your company can immediately begin reducing scrap, rework, production downtime and realize a rapid ROI for your SPC software investment. “Once we implemented Synergy, we immediately saw results. For us, a process that used to take a day was reduced to an hour and ½. Synergy easily paid for itself in a couple of weeks,” said Bob Hayes, VP of Engineering Services for Foam Design. “Synergy ensures we make good parts and keep the cost of defects down. We found that the product paid for itself in 4 months,” said Dan Heimann Quality Manager for MASS Precision.

Synergy 3000 Web Operator Capability Chart

Synergy Software Validation

Cincinnati, OH—May 7, 2013 —Zontec Inc. the international developer of Statistical Process Control (SPC) software solutions, today announced a new Synergy SPC software validation service to its customers. “This package will be invaluable to our customers and prospects regulated by the Food and Drug Administration (FDA) 21 CFR Part 11,” said Zontec President Warren Ha. “We developed this service to aid companies in the food, healthcare, pharmaceutical, medical device, and other industries to meet the required regulations.” The Zontec Validation Package includes a User Acceptance Testing (UAT) Protocol template, and a UAT Report template to meet the regulatory requirements for electronic recordkeeping and electronic signatures. The key components of the UAT Protocol template consist of the requirements, specification of the system configuration and security, and test cases that demonstrate correct system operation. “This service provides customers with two options: we provide customers the materials necessary to perform their own software validation or we perform it for them,” noted Ha.

Benefits of using Zontec’s Software Validation Package:

• eRecords are less expensive and more accessible than paper records
• eSignatures are much more secure than handwritten signatures
• Personnel time saved from developing validation materials
• Proven SPC software materials that meet regulatory standards
• Adherence to regulatory requirements causes increased productivity
• Cost of compliance is low compared to recalls, penalties and fines

###

About Zontec

Since 1983, Zontec has been providing statistical process control (SPC) software to industry-leading companies across the globe. Zontec is highly respected for its continued focus on innovation and for constantly integrating new technologies that help businesses address quality issues, strive for long-term continuous improvement, and maximize profitability. Zontec is unique in the industry by offering a full suite of products to meet the needs of companies of all sizes. Committed to an aggressive product development schedule, Zontec software is created, tested, documented and totally supported within the company without outsourcing.This gives Zontec complete control over product development of our products. If a service agreement customer decides to upgrade to the next level of the Zontec product suite they can do so at minimal cost through our 100% Investment Retention program. They will be able to access all their previous data in the new product, minimizing production interruption. Zontec software has been adopted worldwide by more than 5,000 companies, spanning virtually every industrial category.

You can also find this information on the Web:

Synergy 3000 SPC Software Web Manager

Selecting the right Statistical Process Control (SPC) software for your business is an investment. Here are 12 things to consider:

1. Is the SPC Software Tailored for Your Business?

Regardless if your company is one facility or an entire enterprise, does the SPC software accommodate the specific needs of your company size? Does the software provide your operators, managers and engineers their own unique view and capabilities in the system?

2. Can You Realize a Rapid Return on Investment (ROI)?

The SPC software must be easily implemented  and require minimal traing, saving you time and money. Immediately, operators begin preventing defects and focusing on production. Managers can constantly monitor any process regardless of location. Engineers begin analyzing real-time data, suggesting improvements and providing immediate SPC data and analysis to customers or auditors.

 3. Does It Seamlessly Integrate Into Your Production Environment?

Your SPC software data must not only transparently integrate with your production, front and back office applications but also easily import from or export to other applications.

4. Does the Software Deliver Instant Charting & Reporting for All Users?

Operators, managers, and engineers need their own real-time charts and reports to print, save as PDF or email as appropriate. In addition to the standard SPC charts such as variable, attribute, capability and others; you also need the flexibility to immediately query and chart specific data. You need customizable reports, as well as the standard process information, automatic certificate of analysis, management and other reports that help you analyze the profitability of your processes.

5. Does the Software Enable You to Meet Regulatory and Customer Requirements?

 Because all industry requirements are different, your SPC software must be flexible enough to allow you to query unique data fields to meet specific reporting requirements.

6. Does the SPC Software Help You Reduce Downtime, Scrap Rate, and Rework?

Your SPC software should provide real-time data to prevent defects even at another facility or at a supplier site. By automatically emailing specified users before processes are out-of-control, you can prevent defects, reduce rejects, reduce scrap rates and production downtime. This also saves on rework and increases production.

7. Does the SPC Software Ensure Production of High Quality Products?

Your SPC software must statistically verify that you are consistently increasing product quality while delivering products on-time to your customers. Through this continuous improvement process, defects to customers decrease, and you reduce parts inspection.

8. Does the SPC Software Enable You to Develop New Products?

With SPC software that provides you process capability and production data at your fingertips, you can monitor production equipment, and test out new products with your existing equipment.

9. Does the SPC Software Provide a Global View Your Entire Supply Chain?

You need to instantly view SPC data from anywhere in your global supply chain including from supplier locations. Your SPC software must enable you to prevent defects, make process improvements, verify customer requirements, and analyze your business profitability.

10. Does the SPC Software Company that Practices Continuous Process Improvement?

To be competitive, you need a SPC software company that is consistently integrating enhancements and innovative technologies, such as cloud computing, into its product line.

11. Does the SPC Software Company that Provide Personalized Support?

Because production delays cost money, you need a technical support team with an extensive background in quality; engineering, IT and manufacturing; to provide you personalized assistance in configuring and maintaining your system.

12. Does the SPC Software Company Have a Proven Track Record?

You need an industry-leading SPC company that has an established reputation for providing SPC software to any size companies in any industry across the globe.

The Zontec product suite provides all of this and much more. Contact us today to see how we can maximize your business profitability.

Operator at Domestic Fastener & Forge, Inc. using Synergy SPC Software.

Manufacturers of today are striving to integrate all the statistical process control (SPC) software data they are receiving from various applications into one cohesive view of their enterprise supply chain. Manufacturers are looking to utilize innovative technologies to help them continually improve their processes by eliminating scrap, reducing rework, and increasing personnel’s productivity. Their SPC software needs to provide an immediate, global view to analyze the performance of their people, their processes, their production equipment and their suppliers worldwide. With access to real-time data, team members prevent defects before they occur and can verify for customers and regulators that their requirements are met. This immediate, worldwide view of SPC data also allows management to analyze the ongoing profitability of the business.

Just as continuous process improvement must permeate your entire enterprise, your SPC software must also evolve with you to incorporate innovative technologies to help you more efficiently monitor your enterprise, maintain profitability, and enable you to explore new avenues for growth.

Zontec maintains an aggressive product development schedule to consistently deliver industry-leading products to its customers. Zontec incorporates customer feedback and innovative technologies, such as cloud computing, into its product suite. Zontec software is created, tested, documented and supported within the company without outsourcing. Our service agreement provides a 100% Investment Retention program, thus minimizing cost of a product upgrade. All existing data will be accessible in the new product, minimizing production interruption.

“We selected Synergy because of its usability, it was cost-effective, and Zontec’s 100% Investment Retention program. We also liked the fact that if we decide to upgrade all our data banks and data tables will roll right into the next generation product,” said Brian Brooks, Domestic Fastener & Forge, Inc.

“We selected Zontec because they were one step ahead of where our customers were going. We thought the Synergy software would be a very user-friendly package,” remarked April Lusk, Director of Quality for Trident Precision Manufacturing.

You need to test out new product ideas and new business possibilities using your SPC data. “We can see using the data from the Synergy software if we can produce a new product using current processes, before we actually produce the new product,” commented Aditya Deshpande, Quality Assurance Manager for Cumberland Plastics Solutions.

“With Synergy, we are able to show customers at their location the exact machine that would be used to produce the new product, what tolerance the machine is currently running and the capability history of that machine. This type of information shows the customer what they need to see before moving forward. Synergy provides us that edge to win the business,” said Douglas Winfrey, Director of Quality for United Gear and Assembly.

To thrive in today’s economy, your business must evolve through continuous process improvements and develop new avenues of growth. At Zontec, we have made a commitment to our customers to consistently improve our software  to provide them a competitive edge.

The Synergy 3000 SPC Software Web Manager view of current processes worldwide.

With facilities and suppliers across the globe, you need a holistic view to analyze the performance of your people, your processes, your production equipment and your suppliers. With access to real-time Statistical Process Control (SPC) software data, your team prevents defects before they occur and you verify for your customers that their specifications are met. This instant, worldwide view of your SPC data also allows management to analyze the ongoing profitability of the business.

“We can have operators enter data in the plants across the globe, while engineers and managers can monitor the data anywhere in the world. Prior to implementing the Synergy 3000 software, we could not easily get this worldwide perspective, in particular from our plant in China,” said Don Bartlett, Director Quality & Customer Service for Grakon LLC.

Regardless of location, you need an immediate, consolidated view of all your processes. “We selected the Synergy 3000, because we knew we would have one dashboard where we could see the entire quality process,” said Fedele D’Alessandro, General Manager for LMPsrl.

Critical to your supply chain are your suppliers. “The Synergy software gave us the tools to better measure and analyze the quality of the plating we were receiving using SPC data. This gave us the definitive objective measurements, in real-time, to improve quality from our suppliers,“ said Dan Heimann, Quality Manager for MASS Precision. “Being able to reliably collect data facilitates communication between MASS and its supplier base.”

You also need live access to SPC data for your customers. ”Using the Synergy software we can easily pull up the data and act on what we are seeing; it also gives us the ability to access the data anywhere in the world including our customer sites,” said Douglas Winfrey, Director of Quality for United Gear and Assembly.

To excel in today’s economy, you need current SPC data from anywhere in your supply chain.

New Cost of Analysis Report available in the Synergy 3000 v 4.0 SPC Software.

Cincinnati, OH—March 18, 2013 —Zontec Inc. the international developer of Statistical Process Control (SPC) software solutions, today announced an update to the Synergy 3000™ for its customers worldwide. “These new capabilities provide manufacturers a comprehensive view of their SPC data from their global supply chain,” said Zontec President Warren Ha. “Because the Synergy 3000 version 4.0 is built on cloud computing, customers instantly access quality business intelligence data about all their facilities and suppliers regardless of location, on the device of their choice.” Zontec is consistently releasing innovative capabilities for its product line so that users at all levels can increase productivity, reduce product defects, boost production rates, effectively manage production assets, and contribute to the ongoing profitability of the business.

Our customers are pleased with the new enhancements as well. “We recently upgraded to the Synergy 3000, and I really like the new capabilities in version 4.0,” said Tim Stutzman, System Analyst for Oregon Freeze Dry, Inc. “The new alert for operators when a check is due will be very helpful. The keypad feature provides us flexibility for the future. I also think that the customizable Cost of Analysis Report will be beneficial for the business.”

Here is a brief highlight of some of the new cutting-edge features:

• A Cost of Analysis Report to determine which process is incurring the greatest cost
• An automatic Certificate of Analysis Report which includes setup, view and run features
• Three Chart option to display Xbar, Moving Range, and Range Chart
• Ability to view control limits, specification limits and notes all from one view
• On screen numeric key pad option for data input without a keyboard

###

About Zontec

Zontec is a major world player in the statistical process control (SPC) software market, carrying on a longstanding tradition as one of the first companies to offer SPC software for personal computers in 1983. Today, Zontec is highly respected for its focus on innovation and applying new technologies that help businesses address quality issues, maximize profitability and strive for long-term continuous improvement. Zontec is unique in the industry by offering a full suite of products to meet the needs of companies of all sizes. Zontec software has been adopted worldwide by more than 5,000 companies, spanning virtually every industrial category.

The press release is also available at the following locations: