See it in action
Watch the In-Process Quality & SPC workflow
A quick tour of In-Process Quality & SPC — live control charts from PLCs and gauges, Nelson-rule alarms on drift, and capability drill-downs across machines and lines.
Trusted by quality teams in regulated, high-volume manufacturing
120+
Plants live worldwide
8M+
Data points captured daily
6
Industries served
15+ yrs
In manufacturing software
21 CFR Part 11IATF 16949 alignedISO 13485 readyEU GMP & MHRAAIAG MSA & SPC
Why manufacturers choose Zometric SPC
Four ways SPC pays for itself in the first year.
These are the outcomes our customers measure on their own dashboards — not feature claims, but P&L impact.
Reduce scrap & rework by 18–30%
Catch process drift before it becomes defective product. Customers typically see double-digit reductions in scrap rates within the first six months of deployment.
Average across discrete-manufacturing customers, year 1
Reclaim INR 1.62M in annual give-away on a single SKU
Tighten variation enough to reduce safety buffers — over-fill, over-thickness, over-spec. Margin reclaimed without touching pricing or volume.
Real customer outcome · F&B manufacturer · single SKU
Pass IATF, FDA & GMP audits without scrambling
Audit-ready Cp/Cpk reporting, full electronic records (21 CFR Part 11), and validation documentation built in. Audits take days instead of weeks of preparation.
Standard across regulated-industry deployments
Detect drift in seconds, not at end-of-shift
Real-time alerts route to the right person — supervisor, engineer, quality lead — at the moment a Nelson rule fires. Corrective action starts before the next batch.
Across all deployment models
Want to see what these numbers look like for your operation?
A 30-min call covers your industry, your KPIs, your baseline.
How our product helps
From shop-floor measurement to corrective action — one continuous loop.
Zometric SPC unifies what most quality teams stitch together from spreadsheets, PLCs, and email chains. Three steps, one platform.
01Step oneCapture
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. Zometric 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 — up to 2 man-days included with new subscriptions.
- 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.
Read the integration docsdata sources
- PLC · Allen-Bradley CompactLogixlive
- PLC · Siemens S7-1500live
- Vision · Cognex In-Sightlive
- Manual · Op tablet (Line 4)3 ops
- Bulk import · Q3 historicals428k rows
- OPC-UA · Edge gateway14 tags
02Step twoDetect
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. Zometric implements all eight 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.
See all supported chart types03Step threeAct
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 indices explainedSee it on your data, not ours.
Bring sample CSVs to a working session — we'll set up live charts in the call.
Customer outcomes
See how teams like yours are using Zometric.
Browse case studies by your industry, or by the situation you're trying to solve.
Talk to a customer in your industry.
We'll arrange a reference call with a team running SPC at similar scale.
Engagement modes
Three ways to work with Zometric.
Whether you need software in your stack, capability in your team, or a full program implemented — pick the engagement that fits.
Concepts & calculations
The statistics behind what you're looking at.
For the engineers who want to know not just what Zometric is doing, but why. Tap any concept to read the full note with theory, calculations, and references.
Build the depth across your team.
SPC Fundamentals (2 days) and Practitioner Certification (4 days) — live or self-paced.
Frequently asked
Common questions from quality teams.
Don't see yours? Schedule a discovery call — we'll answer it directly.
Which control charts and capability indices are supported?
Variable charts: I-MR, Xbar-R, Xbar-S, IMR-R/S, CUSUM, EWMA. Attribute charts: P, NP, U, C, Laney P. Capability: Cp, Cpk, Pp, Ppk, Cpm, Z.bench, sigma within and overall, PPM expected vs observed. All eight Nelson rules. All calculations validated against AIAG standards and Minitab.
Can I integrate Zometric with my PLCs and SCADA systems?
Yes. Native integration with Allen-Bradley, Rockwell, Siemens, Beckhoff, Cognex, Delta, AutomationDirect, and others. OPC-UA and MQTT supported. Older machines without modern PLCs can be retrofitted via our edge connectors.
Is Zometric compliant with 21 CFR Part 11?
Yes. Audit trails, electronic signatures, role-based access controls, and time-stamped data are all built in. We support pharma, medical device, and other regulated industries with the documentation auditors expect.
How long does implementation take?
Most cloud deployments are live within 30 days. Up to two man-days of historical data import is included with new subscriptions. PLC integration and on-premise deployments are scoped per project; our team handles end-to-end implementation directly — no third-party integrator.
What deployment options exist?
Cloud (SaaS) for manual entry and lower-speed lines. Hybrid (recommended) for multi-site Industry 4.0 deployments — best of both. On-premise for high-speed lines or strict data residency. You can migrate between models as your operations evolve, with configurations preserved.
What does Zometric SPC cost?
Zometric SPC uses a base + add-on user licensing model. The base pack includes up to 3 users; additional users can be added as annual or pro-rated annual subscriptions. Pricing is shaped to your deployment model and number of plants. Schedule a discovery call for a quote tailored to your operation.
Ready when you are
Spend 30 minutes with a Zometric expert.
Bring your situation — your industry, your data, your goals. We'll map you to the right path forward, with no pressure to commit.
Tool enquiry
See SPC on your data
Bring sample CSVs to a working session. We'll set up live charts in the call.
Training
Train your team
SPC, Six Sigma, MSA, FMEA — instructor-led or self-paced.
Consulting
Engage consulting
Multi-plant rollouts, RoI-anchored. We handle scope to embed.
Discovery call
Book 30 minutes
Talk to a Zometric expert about your specific quality program.