Most plants are stuck at the bottom of the SPC Maturity Scale with manual checks, siloed systems, and no real visibility until rework, downtime, or giveaway have already hit the floor. Top-performing operations teams are scaling up their SPC and compounding their gains with every level.
How quality and operations leaders are using SPC maturity to drive performance:
From Paper to Platform: Digitize weight, temperature, and quality checks to reduce manual workload
From Reactive to Proactive: Use dashboards and alerts to catch overfill and missed CCPs before batches are lost
From Plant to Enterprise: Benchmark performance and scale wins across shifts, lines, and sites
Each level unlocks more control, better visibility, and stronger ROI. For example: Weaver Popcorn preserved $30M in revenue by optimizing fill weights across plants.Most teams scale up 2–3 levels in their first year, with SafetyChain guiding the climb. See what’s holding your plant at Level 1 and how fast you can scale.
