SPCQuality & Compliance
Statistical Process Control
Achieve Complete Manufacturing Quality Control Real-time statistical process control on Ignition, with live control charts, rule-based alarms and capability analysis to reduce process variation.
The challenge
As manufacturing processes become more intricate, companies need flexibility, agility and efficiency to stay competitive, and product quality is fundamental to success. Delayed or absent sample collection and inaccurate sample data contribute to quality concerns, while traditional offline SPC systems depend on historical data and cannot support real-time correction of process deviations.
Overview
LOGICAL SYSTEMS Statistical Process Control (SPC) is a collaborative decision-making tool that connects the entire quality team with real-time SPC information, so process variation can be reduced proactively rather than just reacted to. It ensures timely, precise and consistent collection of SPC data, delivers it to the right stakeholders through adaptable control charts and analytical tools, and supports every quality-relevant process on the shop floor, from production and inspection to corrective actions for deviations.
Operators and factory managers can monitor process variation in real time and make prompt online adjustments, while alerts let production teams modify process parameters instantly. Statistical Process Control can also harness historical data from various sources within the plant, turning typical process data into actionable insights on the performance of essential processes. Developed for the Ignition platform, the module integrates with the complete suite of LOGICAL SYSTEMS applications and links the shop floor to business applications.
Capabilities
What SPC does
Enable Your First Line of Defense
- Easily configured to give operators real-time SPC information
- SPC data tailored to each user's needs, reducing the learning curve and resistance
- Operators and decision-makers track vital process parameters in real time
- Alarm dashboards tailored to each user's distinct information needs
Extensive Array of SPC Charts
- Statistical rules detect trends, runs, patterns and anomalies, flagging violations in red
- Control limits calculated automatically from historical data for variable and attribute charts
- Alarms on 3-sigma limits or WECO, Nelson, Juran, Hughes, Gitlow, AAIG, Westgard, Duncan rules
- Process capability (Cp, Cpl, Cpu, Cpk, Cpm) and performance (Pp, Ppl, Ppu, Ppk) indices
- Interactive charts with annotations, custom tooltips and editable notes
- Email or SMS notifications via Ignition Alarm Management when an SPC rule is violated
Variable Charts
- X-bar and Range or Sigma
- X-individual and Moving Range
- Moving Average and Range or Sigma
- Cumulative Summation of Means or Individuals
- EWMA of Means or Individuals
Attribute Charts
- p chart
- np chart
- c chart
- u chart
- Defects Per Million Opportunities (DPMO)
Special Charts and Analysis Tools
- Run chart
- Histogram to view the data distribution
- Scatter plot to view the correlation between characteristics
- Pareto of nonconformities, causes, actions or rule violations
Key Features
- Unlimited sample profiles, charts, tags, data sources and rules
- Extensive connectivity to plant data sources and simple data entry, including import
- Works with mouse-driven workstations and touch-driven tablets and phones
- Visual, exception-based deviation management
- Quick configuration of chart systems and large arrays of sample profiles and specifications
- Background monitoring of process data with configurable notifications
Benefits
Why manufacturers choose SPC
Less scrap and rework
Reduced scrap, rework and warranty claims, as real-time SPC data helps resolve problems before they cost time and money.
Higher productivity
Maximised productivity and improved resource utilisation, with real-time insights that streamline processes and increase throughput.
Fewer manual inspections
Decreased manual inspections and increased operational efficiency, with real-time monitoring that flags potential issues ahead of time.
Reduced costs
Instant adjustments to process parameters help reduce costs while enhancing product quality.
Improved client satisfaction
Consistent production of high-quality products improves client satisfaction.
Easy IT integration
Easy integration with IT systems through centralised set-up and security features.
Ask SPC in plain language
LS Assistant, the AI assistant in every Logical Systems application, answers questions from your live SPC records and shows the sources behind every answer. It keeps learning as your records, work instructions and resolved issues grow, and your data is never used to train AI models.
Answers with sources
Every answer cites the records and work instructions it used.
Your role, your site
It sees only what each user is allowed to see.
Asks before it acts
Every change it proposes needs a person's confirmation and is audited.
18 languages, voice on mobile
Questions, answers and content in your teams' languages.
Integration
Connects to the systems you run
Systems & protocols
- Ignition Alarm Management
- SMS
Datasheet
Statistical Process Control datasheetWorks with
Related solutions
See SPC in action
Book a demo with our engineers, using scenarios from your own plant.