Published: 6 May 2016 | Updated: 17 December 2025

Real-Time SPC & Quality Control Software for Manufacturing

What is Quality Control System (QC)?

Smart QC is a comprehensive quality control (QC) and quality assurance (QA) software with built-in real-time SPC (Statistical Process Control) for manufacturers and service organisations. It helps improve product quality, process consistency, and compliance by replacing manual QC workflows with a digital SPC system that supports faster, more reliable inspection execution.

With Smart QC, teams can automate inspection processes, streamline measurement data collection, and centralise QC records in one platform. This makes it easier to monitor key quality indicators, identify trends early, and respond quickly to out-of-spec conditions—reducing human error, cutting scrap and rework, and improving traceability for audits.

Smart QC also supports stronger quality performance through seamless integration with common metrology and measurement equipment, enabling inspection data to flow directly into the QC/SPC software without manual re-entry. It is compatible with tools such as micrometers, CMM, SmartScope, hardness testers, Keyence IM, and height gauges, helping manufacturers maintain consistent inspection data, meet customer and industry quality standards, and drive continuous improvement.

Common Quality Control Challenges Without Real-Time SPC Software

Inconsistent Quality Control: Difficulty in maintaining consistent quality standards across all production batches.
Manual Data Entry: Time-consuming and error-prone manual data collection and entry processes.
Non-Compliance Risks: Challenges in adhering to stringent quality and regulatory standards.
Inefficient Reporting: Generating comprehensive quality control reports is often labor-intensive and inaccurate.
Lack of Real-Time Monitoring: Inability to monitor quality metrics in real-time, leading to delayed responses to quality issues.
Low Productivity & Efficiency: Inefficiencies in traditional QA/QC processes lead to slower production, higher costs, and reduced output, impacting overall profitability.

Traditional QC measuring process.

Quality Control Software with Real-Time SPC and Device Integration

Smart QC is a game-changer in quality control. By automating inspections and data collection, it ensures consistent adherence to quality standards. Traditional methods involving manual data entry are prone to errors and inefficiencies. However, with the integration of advanced technology, this process is streamlined significantly.

Smart QC System offers a prime example of this transformation. By eliminating human intervention in data collection, the system guarantees accuracy and enables real-time data analysis. This empowers manufacturers to make informed decisions promptly, optimize processes, and maintain stringent quality control standards.

Smart QC features seamless integration with various measuring equipment and devices via Bluetooth, such as digital calipers, digital micrometers, digital height gauges, digital indicator, digital measuring tape, digital plug gauge, coordinate measuring machines (CMM), hardness tester, smarts copes, Keyence IM surface roughness testers, and optical comparators, enabling the generation of Statistical Process Control (SPC) charts for real-time product quality monitoring and out-of-spec alert generation.

This advanced quality control software ensures precise data capture and analysis, allowing manufacturers to maintain consistent product quality and promptly address any deviations. By integrating with a wide range of measurement tools and inspection devices, Smart QC enhances accuracy and efficiency in quality control processes, driving better compliance with industry standards and improving overall operational performance.

Real-Time SPC vs Manual QC: Key Process Improvements

Inspection Process: Manual inspections with high error rates vs. Automated, precise inspections improving accuracy.
Data Collection: Tedious, error-prone manual entry vs. Streamlined, automated data collection reducing errors.
Quality Monitoring: Delayed quality issue detection vs. Real-time quality monitoring for immediate response.
Report Generation: Time-consuming manual reports vs. Instant, comprehensive quality control reports.
Compliance: Struggles with maintaining standards vs. Easy adherence to quality and regulatory standards.

Real-Time SPC Software Features for Automated Quality Control

Automated Inspections: Streamline the quality control process with automated inspections, reducing human error.
Real-Time Data Collection: Capture and analyze quality data in real-time for immediate insights and decision-making.
Customizable Reporting: Generate detailed and customizable quality control reports to meet specific needs.
Compliance Management: Ensure adherence to industry standards and regulatory requirements with automated compliance tracking.
Quality Analytics: Utilize advanced analytics to monitor and improve product quality continuously.
Real Time QC Dashboard: Monitor and manage quality control activities instantly with a real-time dashboard, enabling faster decision-making and improved process oversight.

Real-Time SPC Benefits: Accuracy, Compliance, and Cost Reduction

Improved Accuracy: Automated inspections and data collection reduce errors and ensure consistent quality control.
Enhanced Efficiency: Streamlined processes save time and resources, improving overall operational efficiency.
Real-Time Monitoring: Immediate insights into quality metrics allow for swift action on quality issues.
Regulatory Compliance: Automated compliance tracking ensures adherence to industry standards and regulations.
Better Decision-Making: Advanced analytics provide valuable insights, driving continuous quality improvement.
Cost Reduction: Minimize operational costs through automated quality control processes, reducing waste, and optimizing resource utilization.

Frequently Asked Questions (FAQ)

1. What is Real-Time SPC (Statistical Process Control) software?

Real-Time SPC (Statistical Process Control) software is a digital quality control system that monitors manufacturing processes using live inspection and measurement data. It automatically generates SPC charts, detects abnormal variation, and helps quality teams control critical dimensions, reduce defects, and maintain a stable process.

2. Why use SPC software instead of Excel for quality control?

Excel-based SPC is slow and error-prone because teams must manually enter measurements, update charts, and format reports. SPC software automates data collection, real-time SPC charting, alerts, and reporting—reducing human error, shortening response time, and improving quality assurance and audit-ready documentation.

3. What SPC charts, Cp/Cpk, and quality metrics can Real-Time SPC track?

Real-Time SPC software tracks process stability and capability using common SPC control charts and analytics, including trend detection and out-of-spec monitoring. It supports process capability analysis (Cp/Cpk) and quality metrics that help manufacturers improve process performance, reduce variation, and drive continuous improvement.

4. How does Real-Time SPC improve defect detection and reduce scrap and rework?

Real-Time SPC identifies out-of-control conditions early by detecting shifts, trends, and rule violations before defects escape. By enabling faster corrective action, SPC reduces scrap, rework, downtime, and customer complaints—improving overall product quality and process reliability.

5. Can Real-Time SPC integrate with inspection equipment and digital data collection?

Yes. Real-Time SPC and quality control software can integrate with inspection workflows and measurement devices to capture data digitally instead of manual typing. This improves measurement traceability, reduces data entry errors, and creates consistent quality records across operators, shifts, and production lines.

6. Which industries use Real-Time SPC and quality control software?

Real-Time SPC is widely used in automotive, aerospace, electronics, precision machining, metal fabrication, and medical device manufacturing where tight tolerances and strict quality requirements apply. It helps manufacturers meet customer standards, improve compliance, and maintain consistent process capability.