Statistical Process Control

Continuously monitor and control process quality using statistical analysis. Identify process variation early, reduce scrap, increase production yields, and support Six Sigma conformance through real-time insights and automated corrective actions.

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The Challenge: When Quality Issues Escape Detection

Manufacturing organizations face constant pressure to maintain quality standards while reducing costs and waste. Without real-time statistical monitoring, quality issues remain undetected resulting in scrap, rework, or even quality escapes impacting customers. Manual quality control methods operate slowly, inconsistently, and reactively, limiting the ability to detect process variation before defects occur. When teams lack statistical tools to monitor process capability and process stability, continuous improvement efforts stall and proactive quality control becomes impossible.

Common Challenges

  • Delayed detection of process variation due to manual quality checks
  • Inability to distinguish normal variation from assignable causes
  • Lack of real-time visibility into process capability and stability
  • Quality-related data distributed across disconnected systems
  • Difficulty correlating quality issues with production parameters

Resulting Business Impact

  • Increased scrap and rework costs that reduce profitability
  • Quality defects discovered late in the production process
  • Customer complaints and returns that damage brand reputation
  • Inability to meet Six Sigma conformance requirements
  • Reactive quality management instead of preventive control

Effective SPC solutions must provide real-time statistical analysis, automated alerts, and integrated control actions to prevent quality issues before they occur.

The Solution: Statistical Process Control with GENESIS

GENESIS delivers comprehensive statistical process control capabilities that enable operators, quality personnel, manufacturing engineers, and management to monitor process efficiency and reliability using proven statistical methods.

Through extensive SPC calculations, control charts, and automated workflow technology, GENESIS detects anomalies early and initiates corrective actions based on defined quality conditions, supporting higher process quality, lower operating costs, and Six Sigma conformance.


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Real-World Applications

Continental AG

Automotive Manufacturing

Continental AG applies GENESIS Statistical Process Control (SPC) capabilities to monitor and control quality-critical processes across high-volume tire manufacturing operations. Using real-time data collected directly from production equipment, GENESIS enables manufacturing and quality teams to analyze process variation, assess process capability, and detect deviations that impact product performance. By embedding online SPC analysis, decision workflows, and automated corrective actions into the production environment, Continental gains early insight into quality risks, supports continuous process improvement, and maintains consistent product quality across global manufacturing sites.

Result highlights:

  • Near real-time statistical monitoring of production and product performance data
  • Early detection of process variation using online SPC analysis
  • Improved process stability and product quality across multiple manufacturing sites
  • Reliable quality data availability through redundant architecture and data buffering

"Continental selected GENESIS due to the company’s product scope, in terms of technical solutions, and the flexibility of its available modules. Continental favored Mitsubishi Electric Iconics Digital Solutions’ strong customer orientation, the flexibility and availability of its employees, and the fact that they were solution-oriented."

Sebastian Amlong
DOPAC Project Lead, Continental AG

Scholle IPN

Packaging Manufacturing

Scholle IPN applies GENESIS Statistical Process Control (SPC) and real-time production monitoring to standardize quality and performance analysis across a globally distributed manufacturing footprint. Using GENESIS to collect, calculate, and visualize SPC, OEE, scrap, and downtime metrics directly from production equipment, Scholle IPN replaces manual data handling with automated, consistent calculations across all sites. Real-time SPC analysis enables early identification of quality and process deviations, while unified dashboards and mobile data collection support faster response, reduced human error, and cross-site performance comparison. By centralizing production data and normalizing quality metrics, Scholle IPN strengthens continuous improvement efforts and drives more proactive process control across global operations.

Result highlights:

  • Automated SPC, OEE, scrap, and downtime calculations across all production sites
  • Early detection of quality and process deviations using real-time SPC dashboards
  • Reduced human error through elimination of manual data entry and calculations
  • Standardized quality metrics enabling cross-site comparison and collaboration
  • Faster response times and improved continuous improvement decision-making

"By harnessing the Mitsubishi Electric Iconics Digital Solutions software and their domain expertise, our equipment now tells our associates where the problem is and the impact it is having. We have enhanced our ability to proactively analyze quality and mechanical data, nurturing faster response times and even elements of prediction through SPC."

Martin Molloy
Global Continuous Improvement Manager, Scholle IPN

Operational Outcomes and Business Benefits

Reduce Scrap and Increase Yields

Built-in control charts, statistical graphs, and alarm views enable early identification of quality outliers, reducing scrap and improving production yields.

Real-Time Quality Control

Real-time SPC data supports trend analysis and informed decision-making, enabling proactive quality management instead of reactive problem-solving.

Automated Corrective Actions

Integrated workflow technology initiates control actions based on defined quality conditions or alarm violations, enabling automated adjustments to PLCs, controllers, and DCS systems.

Enterprise-wide Quality Programs

Scalable architecture supports enterprise-wide SPC initiatives, including applications requiring rapid sample rates and distributed data collection.

Statistical Process Control Capabilities

Extensive SPC Calculations and Control Charts

Flexible configuration of sampling plans and a comprehensive set of statistical calculations can be applied to process variables. Generate standard control charts, including X-bar, R, S, Individual X, Moving Range, P, NP, C, and U charts. Integrate SPC results into expressions and logic to drive corrective actions based on observed process trends.

Visual Analysis and Dashboards

Analyze SPC data using histograms and control charts that highlight samples violating statistical rules, supported by detailed tooltips explaining each violation. Create customizable portal dashboards and containers to visualize quality data across devices. Generate standardized quality reports to support compliance and continuous improvement initiatives.

Integrated Alarming and Notifications

Automatically generate alarms when statistical rule violations occur, notifying operators and quality personnel in real time when abnormal operating conditions arise. Configure alarm sequences to escalate issues and initiate workflow-based corrective actions.

High-Performance Data Collection

Leverage GENESIS historian capabilities to support efficient data collection and high-speed statistical calculations. Monitor system efficiency and reliability using statistical methods. Configure SPC tags, distribution rules, and statistical calculations with flexible sampling levels, ranging from individual measurements to subgroups and lots.

SPC with GENESIS: Flexible, Scalable, and Simple to Deploy

Statistical Process Control capabilities in GENESIS offer the flexibility to be configured in a wide range of quality monitoring applications. The GENESIS platform enables organizations to monitor processes continuously, identify quality deviations early, and take corrective action proactively to improve performance and maintain Six Sigma conformance.

Key platform capabilities:

  • Configurable sampling and extensive SPC calculations to identify quality issues
  • Control charts and portal dashboards accessible across devices and locations
  • Integration with production parameters to correlate quality data with process conditions
  • Asset-based organization using ISA-95–compatible structures to support enterprise-wide analysis
  • Workflow technology that initiates automated responses to defined quality conditions

Organizations operating in quality-critical environments require continuous analysis and real-time quality control to meet Six Sigma or higher conformance targets. GENESIS provides the statistical analysis, visualization, and automation capabilities needed to reduce waste, lower operating costs, and gain deeper insight into process performance and process capability—supporting improved overall quality and higher customer satisfaction.

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