In-Process Quality
Quality Built Into the Process, Before Loss Occurs
In-process quality only works when deviations are corrected immediately—while product is still on the line. SafetyChain brings real-time quality checks, SPC, and corrective action directly into production workflows so teams control quality as product is being made, not after it’s finished. When data drifts out of spec, teams don’t just see it—they act on it. Issues are corrected, verified, and documented before defects turn into scrap, rework, or product holds. The result is tighter process control, protected yield, and consistent quality outcomes without slowing production.
Quality Control That Yields Real Results and Prevents Loss
SafetyChain customers report measurable reductions in waste, tighter process control, and significant yield improvements by correcting quality issues as they happen—not after production is complete.
20–30% Waste Reduction
One manufacturer reduced waste by up to 30 percent by using in-line quality checks and SPC trends to trigger immediate corrective actions before variation escalated into defects.
$20M in Yield Gains
By automating weight control with real-time SPC, corrective workflows, and automated response, one producer reduced overpack and giveaway across multiple lines, generating tens of millions of dollars in annual savings.
50% Material Usage Cut
A plant-based protein manufacturer reduced batter and breading pickup by half by monitoring in-process variability and enabling faster, verified adjustments on the line.
Stronger Process Capability
One operation improved SPC process capability from Cpk 0.2 to 1.3 by correcting process drift in real time instead of relying on end-of-run analysis.
Correct Deviations While Production Is Running
SafetyChain supports the quality checks and controls required to maintain product consistency while production is running, ensuring issues are corrected before they reach finished goods, customers, or auditors.
- At-Line and In-Line Quality Checks
Capture weights, measurements, sensory attributes, and other critical parameters during production so deviations are identified and addressed before large volumes are affected. - Weight and Attribute Control
Monitor fill weights, formulation parameters, and critical attributes in real time and trigger corrective actions when trends move toward out-of-spec conditions. - Immediate Corrective Action and Verification
Trigger alerts, tasks, holds, and verification steps when data exceeds limits—ensuring deviations are corrected, confirmed, and closed before product moves downstream.
No Lag. No Guesswork. No Late Corrections.
In-process quality breaks down when data is delayed, fragmented, or reviewed after production ends. SafetyChain helps teams stay in control without slowing the line.
Early Issue Detection and Response
Surface trends and shifts in real time and correct them immediately so teams can intervene before small deviations turn into scrap, rework, or downtime.
Faster Decisions
Give operators and supervisors and quality teams immediate visibility into quality performance, eliminating guesswork and delayed responses.
Reduced Giveaway
Keep critical attributes aligned to target using real-time data and controlled adjustments instead of conservative buffers or end-of-shift review.
Controlled Product Release
Identify and manage potentially nonconforming product during the run, reducing downstream risk and disruption.
Serious Quality Control, Minus the Friction
- Real-Time In-Process Data Capture
Collect weights, pH, viscosity, label checks, and other parameters using configurable digital forms at defined control points. - Statistical Process Control (SPC)
Monitor variation and trends as production happens, with built-in action instead of passive analysis. - Automated Alerts and Workflows
Trigger notifications, tasks, corrective actions, and follow-up actions when data exceeds thresholds or required checks are missed. - Operator-Focused Dashboards
Provide clear, mobile-friendly visibility into in-process quality trends for frontline teams, supervisors, and quality leaders. - Product Hold Management
Control and document potentially noncompliant product during production to prevent unintended release. - Targeted Reporting and Analytics
Analyze in-process quality data by product, line, or shift to reduce variability, protect yield, and support customer and compliance requirements.
Trusted by Food & Beverage Manufacturers
Plant Impact Spotlight: Blue Bell Creameries
With access to real-time digital data with SafetyChain, Blue Bell Creameries streamlines food safety, quality control, and audits, making information instantly accessible and improving decision-making.
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How Fresca Integrated Quality and Production Systems to Keep Up with Growth
As one cohesive unit, Fresca now makes decisions together, whether that’s tackling an issue or simply seeking new ways to improve. Quality and production now work hand-in-hand without silos, and their automated, data-driven approaches have propelled them into new areas of excellence.
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Build Stronger In-Process Quality With SafetyChain.
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