Whether it be a customer or regulatory audit, each one is unique.

Proactively preparing is the key to success:

  • Documented processes in place
  • Historical data to verify that your processes are in-control or in-specification
  • Worksheets or visual aids to train your operators properly
  • Appropriate procedures to follow if something is out-of-control or out-of-specification

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Measuring Product Weight

Product measurements and weights are often an issue for companies that produce food products. In a recent incident where a major food manufacturer was cited for their products being underweight, Judy Cardin, the chief of weights and measures for the Illinois Department of Agriculture, Trade and Consumer Protection called the shortages:

“’very significant … These kinds of shortages should never be leaving the plant.’”

When a gram can cost you a significant sum of money, you want to make sure that your machines are running at optimal efficiency without compromising customer expectations. That is where Statistical Process Control (SPC) comes in. SPC software ensures that your product stays within control and within specification.


Are manual processes bogging you down? In 2 weeks you can streamline your data and see the stability and capability of your processes.

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 Company-Wide View of All the Process Performance

Facilitating instant communication, a SPC software package should provide you a company-wide view of all of the processes and how they are performing. The system should notify you if a process is trending towards being out-of-control or out-of-specification. If an issue should arise, a user should be able to right click to instantly email from any chart or report that is open to the appropriate person to take corrective action. This provides for immediate communication and a reduction in errors.

“Using Synergy, we are saving money by decreasing 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.

Food companies are managing the fragile balance between providing the specified amount of product, while still running a profitable company. Leading-edge companies are constantly working to maintain these tolerances.

“Considering we are running 5 packaging lines a day, if we can reduce our range by a gram that saves a lot of money. Since our packaging runs are in the thousands, that gram saves us a ton of money. Without Synergy, we would not be able to set such tight tolerances,” Stutzman said.

Industry leading food and packaging companies manage this balance every day. Companies recognize that issues will occur and build continuous process improvement procedures to prevent them from leaving the plant.



With Ongoing Recalls, The Automotive Industry Has a Challenge When It Comes to Quality. 

That is why the auto industry developed the Automotive Industry Action Group (AIAG) in 1982 as a not-for-profit association where professionals from a diverse group of stakeholders work collaboratively to streamline industry processes via global standards and harmonize business practices. AIAG standards are involved in the production of virtually every car in the United States, as well as the international production of American automotive companies. With 750 member companies covering every step of the supply chain, AIAG standards define the industry.

AIAG has made Statistical Process Control (SPC) a requirement for supplying the US automotive companies. Implemented well, SPC software can enable suppliers to profitably meet their automotive customers requirements.

SPC Software Meets AIAG Automotive Requirements and More

Putting in place a high quality SPC software product will not only meet these AIAG requirements, but also enable your company to eliminate scrap, reduce rework, maximize employee productivity, and proactively look at areas for improvement. Through:

  • Maintaining your desired Sigma level
  • Monitoring more closely the lifecycle of your equipment
  • Reducing your customer defects to zero
  • Using your SPC data to test out the viability of improvements to the production line
  • Working closely with your suppliers to prevent rejects before they occur

Here is one example. Grakon LLC is a global leader in the design and development of advanced lighting systems and engineered trim components for premier Original Equipment Manufacturer (OEM) vehicle manufacturers. Don Bartlett, Director of Quality and Customer Service for Grakon LLC uses Synergy 3000 to meet their AIAG capability requirements.

“Typically, the standard is a Cpk of 1.67, however, our internal goal is to be greater than 2,” Barlett said. ”Synergy 3000 has really helped us with quality system compliance, and continuous improvement.”

A photo of Schoeneck Containers operator using Synergy 2000 SPC software on shop floor.

An operator at Schoeneck Containers uses Zontec’s Synergy 2000 SPC software on shop floor.

The Plastics Engineering website is highlighting Schoeneck Containers using Synergy 2000 to save 33 man-hours a day!

In the article, Scott Chambers, Quality Facilitator  for SCI, says he likes the mult-tiered approach to the Synergy Statistical Process Control (SPC) software.

“I like the fact that with Synergy SPC software we have three levels of operation to protect the data; the operator, manager and engineer levels,” said Chambers. “I also appreciate how easy it is to cut and paste information from Synergy to share with customers. This is a feature that differentiates Synergy from other SPC packages out there. And although this happens relatively infrequently, I like the fact that during a customer audit, they can view the information real-time in Synergy.”

MASS Precision operators using Synergy SPC software on production floor.

MASS Precision using Synergy SPC software on production floor.

When it comes to supplier management, good data makes all the difference, according to Dan Heimann of MASS Precision, Inc. during the Zontec Best Practices: Supplier Management Webinar. Because your suppliers affect the product you ultimately deliver, making sure that their products are made correctly becomes part of your job. You need quality information to share with your suppliers that tells them how they are performing. You need information that tells you before your suppliers’ product goes out-of-control. Where do you get this information? From the Statistical Process Control (SPC) software data that you are collecting. Capturing this SPC data can help you:

  • Prevent defects before they occur
  • Reduce rework
  • Eliminate customer rejections

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