Three real-life examples showing how leading manufacturers are putting SPC to work in their food, beverage, and CPG plants to improve productivity, quality, yield, and profitability.

1. Beyond Compliance
Putting SPC to Work in Your
Manufacturing Plant

2. The Sponsor
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Plant Management Platform
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3. Before we get started
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Helpful tips
✔ Informal, conversational approach
✔ Ask Questions (Q&A at end)
✔ Only panelists are displayed/heard
✔ Recording link will be shared
✔ Slides will also be shared
✔ Audio issues? Use call-in number

4. About the Presenters
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Shamonique Schrick
Solutions Architect
Eric Hansen
VP Technical Solutions
● Over 10 years of experience as an auditor, food
safety expert, and quality specialist
● Degrees in biochemistry and molecular biology
● Treehouse Foods, Cargill, MillerCoors, CSM
Bakery
● Over 20 years of experience across Healthcare,
Logistics, Manufacturing
● Expertise on safety, compliance, operations, and
quality programs
● 9 years at SafetyChain

5. Benefits of SPC
Reduce cost,
manage waste &
rework
Increase efficiency
& productivity
Comply with FDA,
FSMA, USDA, etc
High spec
conformance
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Visibility into
process variability
for informed
decisions

6. What is SPC (Statistical Process Controls)?
✔ Uses statistics to:
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✔ SPC tools provide process level
visibility:
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7. Control Charts - Xbar-R & Xbar-S
✔ Periodic samples plotted over time
✔ Xbar (Mean Chart):
✔ XBar-R (Range Chart):
✔ XBar-S (Sigma Chart):
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8. Control Limits & Run Rules
✔ Control Limits
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✔ Run Rules
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9. Histogram - Process Variation
✔ What is process variation?
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✔ How do you account for process
variation?
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10. Process Capability Measures - Cpk & Ppk
✔ Shows how well production conforms to specifications
✔ Cpk = 2 is 6 Sigma: Cpk < 1, not capable of meeting specification
✔ 1.33 Ppk = 99.99% of all materials are within specification
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11. 3 Cases of SPC
in Action

12. Case 1: Optimize Yield
Example: Cook Temp
Outcome: Optimize yield subject to
compliance requirement
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14. Temperature Variability, Low Yield
Oven Baked Cookies or Bread
• Bread: Too Hot temperatures - baked
unevenly, misshaped product, Too Low -
raw product, dense loaves
• Cookies: Too Hot - cookies will spread
too much (melted), Too Low -
underbaked, pale and no spreading
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15. Case 2: Minimizing Giveaway
Example: Package Weights
Outcome: Minimize give-away, subject
to compliance requirement
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18. Case 3: Package Weight - Lotions
Shea Butter Lotion. It’s not easy.
• Too light? Too fluffy? Thin? This
can miss minimum weight
• Too dense? Too heavy? This can
mean overfill OR rework
• Specific gravity and overall
package weight are variables
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19. Example: Real time operational
control: pH Viscosity
Outcome: Meet both ends of the
requirement.
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Case 3: Multi-Attribute Control

21. Acidified Foods + Hot Fill Hold
Fruit Fillings: pH, Temp, and Viscosity
• pH <4.6
• Hot Fill - used to sterilize packaging
• Affect the quality of the product
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23. Building an SPC Program in Your Plant
● How can we impact
performance?
● What are those data
points?
● Set improvement goal
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● Where to find data
● How to deploy and
monitor - who?
● Tool setup and
maintenance
● List control charts
● Active monitoring
● Review with teams
● Visibility/shareability is
key
● Review goals - miss?
Hit? Rinse/repeat
● Troubleshoot off
quality issues

24. POLL
What best describes your use of SPC?

25. A few tips to leave you with...
✔ Risk/impact assessment of the operation (can just be a line) to identify key
processes and attributes
✔ Understand how those attributes affect overall performance and how weight, pH,
viscosity, cook temp affect margins, profit, yield, and compliance
✔ Ask around - has anyone in your plant done this before? Has another
plant/facility? Be curious!
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26. Q&A
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27. Resources
White Papers & Surveys
Webinars & Videos
Product & Partner Info
Solution Consolation
Learn more at SafetyChain.com
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