In-Process Quality & Statistical Process Control (SPC)
Digitize quality checks, establish real-time control charts, and enforce OCAP compliance to catch process drift before your batch fails.
Verifiable enterprise projects delivered for leading global brands.
Bridgestone
Tire Manufacturing
Schindler
Pulley Concentricity
Tata AutoComp
TQM Portal
Sandvik
Vehicle Management
Est. 2013
Active engineering and consulting partner for 13 years.
Fortune 500 projects
Verifiable manufacturing systems delivered since 2017.
Defense-Grade Systems
Secure operations tracking built for the Government Army in 2022.
Engineered for Quality Leaders & Frontline Operations.
Designed to replace manual paper sheets and disconnected spreadsheet reviews with real-time process integrity.
Who this is for
Quality Engineers
Engineers responsible for running control charts, configuring capability studies (Cp/Cpk), and analyzing process distributions.
Line Supervisors
Supervisors on the shop floor tasked with identifying process drift and tool wear before a batch fails or escapes.
Plant Quality Managers
Managers who need audit-ready compliance evidence, secure electronic records, and traceable correction histories.
Modernizing Manufacturers
Operations currently relying on manual paper checklists or end-of-shift spreadsheet reviews instead of real-time control charts.
Real Operational Outcomes
Verified results delivered across Pure Technology's manufacturing engagements.
Raw Material Testing (MTR)
Replaced manual raw material record checks with IoT data capture and AI predictive quality checks, resulting in 90% fewer errors in test reports and 50% better traceability.
Verified Client Project
Bridgestone Digitalization
TQM Operational Portal
Digitized abnormality management, safety audits, and lean tools (5S, Poka-Yoke) to reduce repetitive defects by 40% and increase Kaizen submission by 60%.
Verified Client Project
Tata AutoComp Portal
Pulley Concentricity Inspection
Developed custom GED software matching high-precision engineering gauge inputs for elevator pulley concentricity inspection, ensuring automated quality validation.
Verified Client Project
Schindler GED Software
Production KPI Dashboard
Centralized production output, scrap monitoring, and downtime logs across departments, driving a 20% efficiency boost and 40% faster reporting.
Verified Client Project
Bridgestone KPI System
Vehicle Access Control
Integrated RFID/FastTag scanning with boom barrier controllers and corporate SSO to achieve 90% automated gate clearance and 80% live visibility.
Verified Client Project
Sandvik Gates System
8D Complaint Resolution
Digitalized the structured 8D complaint management methodology, replacing paper logs with automated notifications and root-cause verification workflows.
Verified Client Project
Tata AutoComp QR Board
Meet your data where it already lives.
Quality data takes different forms on different lines — manual entry on operator tablets, bulk Excel imports for historical loads, or fully automated capture from PLCs and IIoT sensors. Pure Technology handles all three on the same platform, with the same data model.
- PLC & IIoT integration with Allen-Bradley, Siemens, Beckhoff, Cognex, AutomationDirect, OPC-UA, MQTT.
- Operator-friendly manual entry with multi-sample subgroups, validation, and offline sync.
- Bulk historical import — quick onboarding for your historical quality records.
- Edge connectors for legacy machines — retrofit older equipment without ripping out your stack.
Outcome: One quality data lake across every line, every plant — without changing your existing automation stack.
Diameter measurements on Line 3 show 9 consecutive points above the centerline. Process is technically in control, but trending — investigate before further drift.
Catch the right signals — not the noise.
A control limit breach is the obvious signal, but processes drift in detectable patterns long before any single point goes out. Pure Technology implements Nelson rules and lets you toggle each one independently per chart — so sensitivity tracks process maturity, not theoretical defaults.
- Variable charts — I-MR, Xbar-R, Xbar-S, IMR-R/S, CUSUM, EWMA.
- Attribute charts — P, NP, U, C, Laney P (with variable subgroup sizes).
- All 8 Nelson rules, each toggleable per chart.
- Granular alert routing by Product × Process × Parameter.
Outcome: Engineers stop drift before it becomes scrap — corrective action starts before the next batch.
Capability and corrective action — closed loop.
Every signal becomes structured data: assigned cause, corrective action, follow-up. Capability indices are recalculated on the latest stable window — Cp, Cpk, Pp, Ppk, Cpm, Z.bench, sigma within and overall — so engineering decisions ride on current truth, not stale reports.
- Cp, Cpk, Pp, Ppk, Cpm, Z.bench — all AIAG-validated.
- Normal & non-normal — Anderson-Darling, Shapiro-Wilk, Box-Cox, Johnson.
- Capability six-pack — diagnostic standard for new product introductions.
- Special-cause capture — every violation logged with assigned cause and follow-up.
Outcome: Capability targets met for IATF and FDA audits — without weekend war rooms before the audit window.
Capability — SKU-7842 / Diameter
Window • last 30 days • n=2,841
Real-Time Control Charts
Monitor process centering and variability as parts are measured. Instantly generate X-bar R, X-bar S, or I-MR charts with automated drift detection using standard statistical rules.
Nelson's Rules Recognition
Flag process shifts and runs before parts violate specifications.
Custom Control Zones
Divide charts into A, B, and C zones to analyze distribution spreads.
Dynamic Limit Locks
Lock calculated baselines to prevent unauthorized boundary shifts.
Automated Data Ingestion
Map variables to digital micrometers, thickness gauges, and scales.
Line 3 Outer Diameter (X-bar R)
Subgroup Average & Range chart
Alarm Triggered
Nelson Rule 2: 9 consecutive points above Center Line
Abnormality Containment (OCAP)
OCAP-2026-894Nelson Rule 2 Alarm (Line 3)
CTQ Parameter: Outer DiameterOut-of-Control Action Plans
Ensure operators execute standardized corrective procedures the moment an alarm sounds. Enforce containment logs, capture calibration photos, and route signs to quality managers.
Enforced Step-by-Step Logic
Guide crews through interactive recovery workflows based on failure modes.
Mandatory Evidence Uploads
Require photos of tool alignment, gauge values, or material labels.
Traceable Audit Ledgers
Log every validation step and operator comment to satisfy FDA and IATF audits.
Automated Escalation Loops
Instantly alert quality engineers if OCAP steps fail to correct process offsets.
From The Shop Floor To The Leadership View
Our statistical process control workflow connects every operation level from frontline checks to regulatory reviews.
Operator measurement logs
Operators log dimensions directly at line terminals, receiving instant visual feedback when a point exceeds control limits.
Out-of-control notifications
Statistical engine evaluates points against Nelson's rules and instantly routes alert notifications to assigned quality engineers.
Audit-ready capability reports
Export compiled Cp/Cpk capability indices and unalterable electronic signature logs for external auditors with a single click.
Enforcing OCAP execution
When an alarm is triggered, operators are guided through the Out-of-Control Action Plan (OCAP), requiring digital sign-offs.
Standardizing chart templates
Distribute consistent X-bar R and I-MR chart layouts centrally across lines while restricting limit-modification privileges.
Validating alert accuracy
Track false-alarm ratios on pilot lines, adjusting and optimizing control limits before rolling out across the entire facility.
Demystifying Statistical Concepts.
Understand the core logic powering Statistical Process Control (SPC). Tap any concept card to expand details.
Common cause variation is the natural, expected background fluctuation inherent in any process (e.g. minor environmental changes). Special cause variation is an assignable, unexpected event (e.g. tool break, raw material batch shift) that shifts the baseline and requires immediate containment.
Control limits (UCL and LCL) are calculated statistically to encompass 99.73% of normal process variation. By placing limits at +/- 3 standard deviations (3-sigma) from the center line, any point crossing a limit represents a statistically significant deviation (99.73% confidence) that cannot be attributed to random noise.
Cp measures the potential capability of a process, comparing the tolerance width (specification limits) against the natural width of process variation, assuming the process is perfectly centered. Cpk adjusts this capability for centering, showing how close the process distribution actually is to the nearest specification limit. A process can have a high Cp but a low Cpk if it is drifting off-target.
Process drift is not just a single point crossing a control limit. We monitor patterns using Nelson's rules—such as 9 consecutive points on one side of the center line, or 6 points steadily rising or falling. These indicators alert quality engineers to process shifts before parts violate physical tolerance thresholds.
A Repeatable Path to Plant Scaling
Our structured rollout process is focused on validating statistical limits and operator workflows before scaling site-wide.
Discover — Week 1-2
Map current workflows, select which lines to monitor first, and identify critical-to-quality (CTQ) product characteristics.
Configure — Week 3-5
Define control plans, set initial control limits, and configure X-bar R or I-MR charts on frontline screens.
Pilot — Week 6-10
Run live measurements on a single production line, validate OCAP workflows, and verify alert and alarm accuracy.
Scale — Week 11+
Roll out control chart types and locked limits across assets, production lines, and multi-site operations.
Industrial technology your operation can rely on.
We combine real-time PLC integration, analytical processing, and compliance frameworks to keep process measurements secure and audit-ready.
PLC / Sensor Capture
Real-time edge ingestion
Operator Terminals
Responsive digital entry
LIMS Integration
Quality lab interfaces
Three ways to work with Pure Technology.
Whether you need software in your stack, capability in your team, or a full program implemented — pick the engagement that fits.
Pure Technology Software Implementation
Deploy Pure Technology SPC into your existing manufacturing stack. Cloud, hybrid, or on-premise — your choice, our setup.
- 30-day cloud deployment
- PLC & SCADA integration handled
- Historical data import included
Training & Development
Build statistical fluency across your team — from operators reading control charts to engineers running multi-factor DOEs.
- SPC, MSA, FMEA, Six Sigma tracks
- Instructor-led, on-site, or self-paced
- Certification programs available
Consulting Engagement
End-to-end program rollouts with measurable RoI. We handle scope, deployment, change management, and embed cleanly.
- 4–12 month engagements
- 2–4 consultants embedded
- 3–8× year-1 RoI typical
The questions we hear most.
Which control chart types are supported?+
We support standard control charts including X-bar R (Average and Range), X-bar S (Average and Standard Deviation), I-MR (Individual and Moving Range), and p/np/c/u attribute charts. All charts dynamically highlight points violating Nelson's rules or custom process control zones.
How fast do we get alerted when a process drifts?+
Alerts are sent in near real-time. The moment an operator logs a measurement or a sensor feeds a data point that triggers an out-of-control rule, the system routes notifications via SMS, email, or Andon beacons to the assigned quality engineer.
Can this replace our current Excel-based SPC sheets?+
Yes. We replace manual data entry and offline Excel macros with real-time digital entry, automated Cp/Cpk calculation, and secure database storage. This eliminates formula errors and ensures control limits cannot be manually bypassed or altered without authorization.
Is this compliant with IATF/FDA/21 CFR Part 11 audit requirements?+
Yes. Pure Technology supports full electronic record compliance including automated, unalterable audit trails, electronic signatures for OCAP sign-offs, role-based access control, and secure version history for limit changes, aligning with 21 CFR Part 11, IATF 16949, and ISO 13485 requirements.
Can operators use this without statistics training?+
Absolutely. The complexity of Nelson's rules, Cp/Cpk math, and control limit calculation runs in the background. Operators simply see clean, color-coded inputs (Green for in-control, Red for out-of-control) and clear, step-by-step instructions for Out-of-Control Action Plans (OCAP).
Free consultation
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Ready to scope this in detail?
A 30-minute call with a senior engineer. No sales theatre — just a real assessment of fit, scope, and timeline.