Custom SPC software development

SPC software supports statistical process control: the systematic measurement of product characteristics and process parameters to monitor whether a production process remains stable and predictable. The software collects measurement data from production, plots it on control charts, calculates process capability such as Cp/Cpk and Pp/Ppk, and gives a signal as soon as a process threatens to move outside the control limits. This allows you to intervene based on trends, rather than only once defects appear. Custom software lets you configure this around your own characteristics, machines and quality standards, rather than forcing you to adapt your way of working to a standard package.

We build the common control charts for both variable and attribute data. For variable measurements, these include X-bar & R and X-bar & s for subgroups, and individuals with moving range (I-MR) for individual observations. For count data, we support p, np, c and u charts. In addition, the software calculates process capability and process performance: Cp and Cpk for short-term process capability, and Pp and Ppk over a longer period, with upper and lower specification limits and the chosen subgroup size. We document and test the calculation engine, so that the results are reproducible and auditable.

We tailor this to your situation. Operators can enter measurements manually through an on-screen form built around the control plan characteristics, with immediate feedback on whether a value falls within limits. We can also connect digital measuring instruments such as callipers and micrometres, coordinate measuring machines (CMM), and measurement data from a MES or machine controller via standards such as OPC UA where possible. Importing from CSV or Excel is also an option. The aim is to avoid double entry and to capture measurements as close to the source as possible, while preserving data integrity.

In addition to breaches of the calculated control limits, the software recognises patterns that indicate a disturbance before a measurement falls outside the limits. For this we use signal rules such as the Nelson rules and the Western Electric rules, for example seven consecutive points on one side of the mean, or a continuous trend of rising or falling values. In laboratory and measurement contexts, where relevant, we apply the Westgard rules. You configure which rule set is active per characteristic. When a signal occurs, a notification is sent to the appropriate role, optionally with a mandatory response or corrective action.

Yes. We connect to digital measuring instruments and coordinate measuring machines for automatic data capture, to a MES or machine controller for process parameters via OPC UA or Modbus, for example, and to your ERP for order, part and batch data. On the quality system side, we link an SPC signal to a deviation or corrective action, so follow-up is traceable. We build each integration around your existing IT landscape and document it, including the measuring equipment register, so you can always trace which calibrated instrument was used for a measurement.

SPC is a core part of the quality approach in manufacturing and in the automotive sector. Our software supports the evidence base for ISO 9001 and IATF 16949 by recording measurements, control charts and capability studies centrally and traceably, with date, measuring instrument, operator and control plan revision. You can export capability reports and control charts as evidence for audits, customer assessments and PPAP files. We do not claim certification on your behalf, but we build the recording and reporting so that you can demonstrate your own process.

We build custom software. No two production environments measure the same characteristics, with the same tolerances, machines, measuring instruments and control plans. Custom SPC software is designed around your actual process: your characteristic structure, your subgroup sizes, the rule sets you apply and the integrations you need. After an initial discovery phase, we agree together which functionality matters most and the order in which we build it, without promising a fixed timeline or price we cannot yet substantiate. The software can grow with you as your product lines, standards or machine park change.

We build for manufacturing companies that want to keep their process quality under statistical control: series and batch production, automotive suppliers delivering under IATF 16949, precision and machining companies, and the quality and QA departments that need to manage control charts, capability studies and reporting. The software supports both the operator on the line who needs to enter a measurement quickly and the quality engineer who analyses trends by machine, product and characteristic and accounts for them to customers and management.