On-line SPC for "Lotions & Potions" Manufacturer
A manufacturer of a variety of creams, lotions and soaps required an on-line system as part of a corporate initiative to improve quality and reduce defects

They identified Critical-to-Quality parameters and shop floor devices to measure these attributes:
Both on-line and historical SPC was required. Real time process monitoring of alarms as well as historical reports to view process health over any period of time. A variety of SPC charts and scorecards including X-bar R charts, I-MR charts, P charts, Defects per Million Opportunities (DPMO), and HIstograms were configured. 
 
 
Alarms based on SPC rules detect potential issues before a traditional low-limit / high-limit is reached.
 
For example, SPC alarms are generated for:
• 9 or more points in a row on the same side of the mean
• 6 or more points in a row are continually increasing or decreasing
• 2 out of 3 points in a row are more than two standard deviations from the mean in the same direction
• 4 out of 5 points in a row are more than one standard deviation from the mean in the same direction

This system was implemented on 9 tube, 5 bottle, 1 jar, and 3 soap manufacturing lines.