What is statistical process control, and can it work beyond battery manufacturing?

Statistical process control (SPC) is a quality method used across manufacturing. It monitors critical measurements during production, such as thickness, weight, or dimensions, and uses control limits to separate normal variation from a real problem, so teams correct the process before defects are made. The AdventSys SPC system was built for battery grid production at Exide Industries. Because products, stages, parameters, and limits are configured in the web application, the same system can be adapted to any process with measurable quality characteristics, such as machined parts, castings, molded components, or packaging.

Can an SPC system read directly from weighing machines and calipers?

Yes. The AdventSys SPC system reads weighing scales and vernier calipers directly over RS232 serial connections, with port settings maintained in the web application, so there is no manual data entry.

Can AdventSys integrate SPC with existing manufacturing applications, ERP systems such as SAP, or MES?

Yes. The AdventSys SPC system can exchange data with ERP systems such as SAP, manufacturing execution systems (MES), and other plant applications. Typical integrations pull product, batch, and specification data in, and send quality results, alerts, or holds back. AdventSys has delivered SAP-integrated manufacturing systems, including work-in-process tracking and traceability for Exide Industries. The integration method, whether APIs, middleware, or scheduled data exchange, depends on what the existing systems support.

Can AdventSys develop a custom MES with SPC?

Yes. AdventSys builds custom manufacturing execution systems (MES) with SPC as an integrated quality module, or as a standalone system that connects to an existing MES. A custom MES can cover production planning, work-in-process tracking, shop-floor data capture, traceability, quality control, and dispatch, integrated with ERP systems such as SAP. For Exide Industries, AdventSys delivered SPC alongside work-in-process (WIP) tracking and traceability with SAP integration. For FANUC India, it delivered an ERP-connected dispatch management system.

Real-Time SPC for Exide Industries

Real-time statistical process control for Exide Industries

AdventSys built a real-time statistical process control (SPC) system for Exide Industries, a top-tier automotive and VRLA battery manufacturer in India. It captures grid weight and thickness at the line, calculates control limits and process capability, and shows quality teams drift before it turns into rejected batteries.

The challenge

For a high-volume battery manufacturer, plate consistency at grid casting and pasting drives yield, warranty cost, and standing with automotive customers.

The manufacturer set out to move quality from inspection after the fact to control during production: live data from every line, statistical limits that separate normal variation from real deviation, and one consistent view across battery types, shifts, and plants.

Why the customer chose AdventSys SPC

Real-time capture straight from the gauges, with no manual entry
Configured for each product, plate type, machine, mold, and shift
Role-based views for operators, QA technicians, and administrators

How it works

The shop-floor workflow runs in a defined sequence:

At the start of each shift, QA technicians assign each machine its plate type, product, mold, and operator; the system blocks a machine from being assigned twice.
Operators log in at the workstation and capture sample weights from the weighing scale and grid thickness from vernier calipers, both connected over RS232.
Thickness is measured at several points on each grid, including the lugs, frame, and wires.
Every reading is stored with its time, shift, machine, mold, and operator.

Analysis

QA filters any period by date, product, plate type, shift, machine, mold, or operator, and the system produces:

Data report: every sample's weight and thickness readings in one table.
Run chart: weight and thickness readings in sequence against the mean, specification limits (USL, LSL), and control limits, so drift shows as it starts.
X-bar and R chart: subgroup averages and ranges, showing shifts in the process center and in its consistency.
Histogram: the distribution of readings across the specification range.
Cp and Cpk: process capability calculated from the same data.

Application modules

Readings flow from the gauges to QA in real time

Operators capture readings at the gauges; QA sets the specification limits and reads the analysis in the web application.

Shop-floor application

Windows application at each workstation, connected to weighing scales and vernier calipers over RS232. QA technicians assign machine, plate type, product, mold, and operator for each shift; operators capture weight and thickness samples.

Users: QA technicians, machine operators

Web application

Masters for machines, shifts, products, molds, employees, users, and gauge port settings. SPC analysis with the data report, run chart, X-bar and R chart, histogram, and Cp and Cpk.

Users: QA technicians, administrators

Email summaries

Sends SPC summary reports to managers by email.

Users: Managers

Reports

Data reports and charts filtered by date, product, plate type, shift, machine, mold, and operator, with export.