MES 3.0

The SPC module implements the policies and procedures of a Quality Management System (QMS).

Use the SPC module for:

  • Manual Sample Collections
  • Automatic Sample Collections
  • Scheduling of Samples based on real-time production conditions
  • Alerting of Samples Coming Due, Due or Overdue
  • Automatic Evaluation of Control Limits and Out of Control Signals without human intervention
  • Alerting of Out of Control Conditions
  • Control Charts

With SPC implemented, quality data in the form of Product or Process measurements are obtained in real-time during manufacturing. This data is then plotted on a graph with pre-determined control limits.  Control limits are determined by the capability of the process, whereas Specification Limits  are determined by the client's needs.

The SPC module in itself provides some very powerful capabilities, and with it sitting on top of the Ignition platform, allows for significant configuration and customization to realize your desired functionality. This module can be used to ensure that statistical data is accurately collected on time, every time, helping you eliminate any issues leading to quality problems. It is an industry-standard methodology for measuring and controlling quality during the manufacturing process. Quality data in the form of Product or Process measurements are obtained in real-time during manufacturing. This data is then plotted on a graph with pre-determined control limits.  Control limits  are determined by the capability of the process, whereas specification limits  are determined by the client's needs.

Automatic Sample Collection

You can collect data from a variety of sources or enter it manually including:

  • PLC devices
  • OPC-connected devices
  • Lab instruments
  • RS232 devices
  • USB devices
  • Data files
  • Web services 
  • External databases
  • Manual data entry

In cases when there is no network connectivity, offline data collection is possible using mobile iOS or Android devices.

On this page:

Lab Instruments

Lab Instruments

For legacy laboratory inspection equipment that does not provide an OPC-UA or other interface, the Instrument Interface module allows for data collection through the parsing of data files or by intercepting data on an RS-232 COM port. See the Instrument Interface help section for more information.

Additional Factors

Sepasoft SPC supports the collection of data not typically associated with quality, but that can directly impact it. These factors can include raw material vendors, maintenance, humidity, temperature and much more.

Scheduling Samples

If you worry about samples being taken at the correct time and not being faked after the fact, you are not alone. It is not a matter of whether or not the person responsible for taking samples has been distracted and missed taking samples, it is a matter of when. The Sepasoft SPC module has powerful features that will schedule samples based on current real time production conditions.

For example, if a lab staff is required to take samples every hour a production line is running, what happens when there is a break down or the production start is delayed because the lack of raw materials? How does the lab technician know when production started and if it has been an hour? In a variety of ways, the Ignition module can let the lab technician know that production has started and a sample is coming due, is due or is overdue. This can be expanded to instantly inform all parties that should know of various sample due states.

This can be utilized for more than taking live process samples. It can also be used for other checks that have to be done around the production facility such as weekly inspections of values or rodent traps.

Simple Automatic Sample Scheduling

Taking accurate, regularly-scheduled samples is vital to maintain quality. That’s why we made it easy to schedule samples automatically in real-time using the Sepasoft SPC Module.

You can take samples based on actual production conditions and use convenient, automated alerts to help ensure that samples are never missed. Customizing a sampling schedule is simple and totally flexible, empowering you to accommodate the requirements of your unique production environment.


The Sepasoft SPC Module makes it easy to ensure that samples are taken on time. A samples list shows upcoming, due and overdue samples by department or location so you can quickly see what's happening. The system can also automatically send out email and SMS notification or flash screen indicators to prompt sample taking. You even have the option of setting up the system to automatically stop production if a sample is overdue.

Sample Approval

When samples are taken, the SPC Module can be set up to automatically approve them or hold them for approval. This feature can help you ensure that samples are approved when and how you need them to be.

Sample Definitions

You can easily create sample definitions to define attributes, control limits, signals and sampling locations. Choose attributes from variable data types such as real, integer, Boolean and many more.

Automatic Alerts for Out-of-Control Conditions

Typically, SPC software requires that someone opens a screen and visually checks for out of control conditions. Just like the scheduling of samples, someone may be distracted by other pressing production issues and fail to complete the task. The Sepasoft SPC module has powerful features that will automatically evaluate out of control signals every time new sample data is recorded. This can be expanded to instantly inform all parties that should know of various out of control conditions.

Quick Automatic Signal Evaluation

To ensure quality, it’s important to keep processes within acceptable control limits. This is done by identifying out-of-control variations as soon as possible without human intervention. Every time a sample is taken, the Sepasoft SPC Module evaluates out-of-control conditions and automatically alerts you if they are present. With the SPC module, find out-of-control variations quickly and resolve them before they become a bigger problem.

Out-of-Control Alerting

The system alerts you automatically whenever an out-of-control condition or bogus sample data has been detected. Alerts are easy to customize so you can have SPC send out an email or SMS notification, flash a screen indicator, stop production, or do a number of other alert methods.

Control Limits

The Sepasoft SPC Module has typical built-in control limit calculations. These typical control limits can be modified or added to simply by editing, copying or creating new ones.


To get you up to speed faster, the SPC Module provides you with standard signals. But when the production environment calls for something more, you can edit, copy or create your own signals.

Analyze SPC Data with Control Charts

All the data in the world is of no use without good analysis tools, so we built the Sepasoft SPC Module with a full range of powerful and flexible SPC Control Charts. Based on security roles, control limit values can be calculated and set interactively on the Control Charts. The Additional Factors feature gives you the flexibility to associate and visualize other production information along with SPC data and with customizable appearance settings for charts, tables, control limits and signals, you have the power to see the information you need in the way you want. The SPC module provides the following types of Control Charts:

Value ChartsAttribute ChartsAnalysis Charts
  • X Bar Range
  • Individual
  • Median
  • X Bar Standard Deviation
  • Process Capability
  • Process Performance
  • P
  • NP
  • C
  • U
  • Histogram
  • Pareto

On all charts, it is possible to add assignable causes and notes to explain a data point. A sample note can be entered on the Lab or Test Stations page when the sample is first entered. This can be done by selecting a sample, then clicking Add Note. An attribute note is added directly from an SPC chart by right-clicking on a data point and selecting Set Note from the drop-down list. In addition to attribute notes, an assignable cause can also be added in this way. Assignable causes can also be saved for future use. Out-of-Control Signals and Control Limits can also be added to the graphs.

Refer to Control Charts for more information.

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