Zometric

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We are an industry 4.0 full stack smart factory solution provider. We digitalise production units and help companies improve their bottomline while managing their supply chain compliances be it internal, upstream or downstream. Some of our key modules include SPC, Inventory management, AI based statistical tool, Production management, MSA, Incoming quality and a lot more.

Zometric Statistical AI

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Statistical AI is the analytical engine behind the Zometric platform: a comprehensive, browser-based statistics suite built for quality engineers, Six Sigma practitioners, process engineers and auditors, not just statisticians. It answers one question: what is the data actually telling you about the process? 130 statistical tools across 14 categories: * SPC Control Charts (19 tools): Xbar-R, Xbar-S, I-MR, P, NP, C, U, Laney-P, Laney-U, CUSUM, EWMA and more, plus Box-Cox and Johnson transformations for non-normal data * Process Capability (12 tools): normal, non-normal, nonparametric, binomial and Poisson capability, machine capability per ISO 22514-3, and Capability Six-Pack * Measurement System Analysis (9 tools): Type 1 GRR, Crossed GRR in AIAG format, Nested GRR, Linearity & Bias, Attribute Agreement, with worksheet generators * Hypothesis Tests (19 tools): t, z, proportion and variance tests, equivalence, normality, outlier, tolerance intervals and bootstrap * ANOVA and Regression: one-way ANOVA, fitted line, multiple regression, logistic (binary, ordinal, nominal), orthogonal, PLS, and ICH Q1E compliant stability studies for pharmaceutical shelf life * Design of Experiments: Definitive Screening up to 48 factors, Full and Fractional Factorial, Mixture DOE, and Response Optimizer * Bioassay (6 tools): parallel line, slope ratio, quantal response, four-parameter logistic and USP cylinder-plate potency methods * Plus Reliability and warranty prediction, Nonparametric tests, Multivariate analysis, Acceptance Sampling (ANSI Z1.4 / Z1.9 AQL plans), 21 graphical analysis tools and random data generators The differentiator: every chart, test and model is read by an AI layer and explained in plain language, written for the engineer, manager or auditor looking at it. Teams stop guessing what a p-value or Cpk means and start acting on it. Built for the standards your regulators and customers already require: AIAG SPC and MSA manuals, ANSI Z1.4 and Z1.9, ICH Q10, and 21 CFR Part 11. Fully browser-based with nothing to install. Works standalone with data from any source, and its APIs embed into every other Zometric module, so the same validated statistics run your live SPC, gauge studies and experiments. Free pilot configurable in 2 to 3 weeks.

Zometric DOE & Experiments Management

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DOE & Experiments Management answers the question every process engineer keeps asking: which parameter combination actually delivers the best yield? It pairs a full statistical Design of Experiments engine with an experiments-management system, so every trial is designed, executed, analysed and archived on the same record. The next engineer who asks "did we try this?" gets an answer in seconds. Statistical DOE capabilities: * Definitive Screening designs up to 48 factors * Full Factorial and Fractional Factorial designs * Response Surface Methodology * Taguchi methods * Mixture DOE for 2 to 7 components * Response Optimizer to find the final settings across one or more responses * Power and resolution computed up front, before runs are wasted, not discovered after Experiments management capabilities: * Design and planning tools: define factors and levels, generate the run sheet, assign runs to shifts * Data collection integration: feed measurements directly from gauges, instruments or Zometric Edge into the experiment record, with no manual transcription and no transcription errors * Experiment repository: a centralised archive of every trial with factors, levels, runs, measurements, conclusions and the engineer who ran it. Searchable, comparable, citable * Knowledge management: search past experiments by material, parameter or outcome. Never repeat a failed trial. Onboard a new process engineer with the full experimental history of the line Every experiment is analysed with the complete Statistical AI engine behind the Zometric platform: main effects, interactions, residuals and optimization, each with a plain-language AI interpretation written for the engineer, manager or auditor reading it. Grounded in established methodology: classical DOE (Fisher, Box, Taguchi), Response Surface Methodology, Six Sigma DMAIC and the AIAG SPC manual. Fully browser-based with nothing to install. Free pilot configurable in 2 to 3 weeks with your real factory data.

Zometric Vision AI

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Vision AI Edge Models bring AI-powered visual inspection to the production line with all inference running on edge hardware. No video streaming, no cloud latency, no bandwidth costs: only the pass/fail verdict syncs to Zometric Core (on-prem or on-cloud), the video never leaves the device. That architecture means full line-speed detection with no throughput compromise, and image data that stays inside the plant. What it detects: * Visual defects: surface cracks, voids, scratches and dimensional errors. Proven on PCBs, stamped components, moulded parts and pharma packaging * Component verification: missing, wrong or misaligned components on assemblies. Solder joints, fasteners, label placement and fill levels caught before they move forward * Anomalies: an unsupervised model flags deviations from baseline with no labelled defect samples needed. Ideal for low-defect-rate and high-mix processes * Sorting and misclassification: wrong variants, mixed-part trays, incorrect orientation and mislabelled items flagged before dispatch or the next operation * OCR and code reading: part numbers, lot codes, date codes and barcodes read directly from the line, automating traceability capture without scanners or manual entry * Person identification: on-device worker registration for PPE compliance detection, fire-drill attendance and skill-matrix-based machine authorisation, so only certified operators run certified stations Deploy from a growing library of pre-trained models or train on your own images. Demonstrated applications include PCB missing-component detection, packaging print quality, flame-colour monitoring, liquid level and label verification. Results feed the Zometric platform's In-Process Quality, Inspection and Continuous Improvement modules with full defect traceability, so a vision-detected defect links automatically to the machine, lot and process data behind it. Serving automotive, electronics, pharma, chemicals and food and beverage manufacturers. Free pilot configurable in 2 to 3 weeks.

Zometric Inspection

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Zometric Inspection answers the question behind every material gate: which lots should you accept, and on what statistical evidence? It digitalizes incoming, in-process and outgoing inspection with statistically valid lot acceptance built into the workflow, replacing paper forms and Excel inspection registers with a tablet-based digital process. The inspector captures once; QA, supplier quality and finance all see the same record. Sampling standards built in: * ANSI Z1.4 attribute AQL plans with Tightened, Normal and Reduced regimes * ANSI Z1.9 variable AQL plans, both sigma-known and sigma-unknown * IS 2500 Part 1 and 2 * c=0 (Squeglia) plans, fixed sample plans and percentage plans * Pick the regime and the system handles the math, including forward-computed switching between Tightened, Normal and Reduced based on lot history, and a dual decision model when both attribute and variable plans apply Three inspection types, one data model: * Incoming, in-process and outgoing inspection, each configured per characteristic and lot, each surfacing the right decision support to the right inspector at the right point in the flow Traceability and audit readiness: * Every inspection record links back to lot, batch, PO, GRN, Challan and Certificate of Conformance. When the customer asks to see the evidence, it is one search away * A full audit trail on every decision: who accepted, who rejected, with what sample, against what AQL, with what disposition. Fully digital and 21 CFR Part 11 compliant where required Built for the standards your regulators and customers already require: ANSI Z1.4, ANSI Z1.9, IS 2500, c=0, IATF 16949 and ISO 9001 quality systems. Part of the Zometric platform, sharing one data backbone with SPC, gauge management and statistical analysis, so a failed lot traces instantly to the machine, measurement device and process data behind it. Browser-based with nothing to install. Free pilot configurable in 2 to 3 weeks.

Zometric Gauge Management & MSA

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Before SPC means anything, the measurement system has to. Zometric Gauge Management & MSA ensures you can trust every reading from every gauge on every shift, combining calibration management and Measurement System Analysis in one auditable system. Gauge management capabilities: * Gauge master and inventory: a centralised register of every gauge across every plant and location, with one record per gauge covering location, owner, calibration cycle, current status and full document history * Calibration scheduling: auto-alerts for due calibrations, certificate management, and status tracking across in-service, due and rejected. Nothing falls through the cracks because nothing depends on a spreadsheet someone forgot to update * Calibration history and audit trails: complete history per gauge, covering who calibrated, when, with what reference, against which standard and with what result * Multi-site gauge control: manage gauges across plants and geographies from a single dashboard. Corporate quality can compare gauge populations, calibration compliance and GRR results across sites Measurement System Analysis capabilities: * Crossed and Nested Gage R&R studies * Type 1 GRR * Linearity and Bias studies * Attribute Agreement Analysis * Standard and AIAG-format reports, ready for the customer's quality engineer to sign off, with AI-assisted plain-language interpretation from the Statistical AI engine behind the platform Built for the standards your regulators and customers already require: IATF 16949, ISO 9001, the AIAG MSA manual, 21 CFR Part 11 and ISO 17025 style calibration programs. Replaces calibration spreadsheets and standalone MSA tools with one system tied to the same data backbone as your SPC and inspection records, so measurement integrity and process data live together. Browser-based with nothing to install. Free pilot configurable in 2 to 3 weeks with your real factory data.

Zometric Thread

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Zometric Thread answers the question every recall and customer complaint starts with: when a customer returns a part, can you trace it back to the supplier lot in seconds? Thread is a traceability and genealogy layer that connects every material, machine, operator and quality event into one unbroken thread from supplier to customer. It is a separately licensed, independently deployable product that works across Zometric and non-Zometric systems alike. Pull any thread, trace everything: * Forward traceability: start from any raw material lot or GRN, trace every production batch it contributed to, every finished goods lot and dispatch note, and every customer who received that material * Backward traceability: start from any finished product or field complaint, trace back to every raw material lot consumed, the machines, shifts and operators involved, and every inspection result linked to that batch * Material genealogy: a complete family tree for any production batch, with multi-level BOM consumed quantities per lot, sub-lot and split-lot genealogy, and exportable genealogy reports for audits * Questions like "which supplier lot caused this customer return", "which customers received products from Batch X" and "what was the full history of serial SN-2024-449" get answered in seconds, not weeks of manual digging Built like a system of record: * Event-driven architecture with real-time thread updates, a structured event schema, subscriptions by module, plant or item type, and an immutable event log with no retroactive edits * Cross-source intelligence: weaves inventory, production and quality data, links maintenance events to affected batches, and connects gauge calibration records to the measurements they produced * External system integration: connects to SAP, Oracle and third-party MES, ingests ERP serial and lot numbers via API. No rip and replace, it augments the existing stack Regulatory coverage: IATF 16949 traceability requirements, 21 CFR Part 11 audit trails on every thread, and FDA, EU MDR and ISO 13485 genealogy reports with one-click compliance export for any batch or lot. Essential for automotive recalls, pharma batch genealogy and food safety programs. Free pilot configurable in 2 to 3 weeks with your real data.

Zometric Inventory Management

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Zometric Inventory Management answers the question every stores audit begins with: do you know exactly what's in every store, in every unit, right now? It gives manufacturers real-time inventory visibility and control across all stores in the plant, where nothing moves without a record. Every movement, tracked: * Multi-store records: live stock levels across raw material, packaging, shopfloor, finished goods and vendor-managed inventory. One source of truth for every store * Goods receipt (GRN) with batch and lot numbers, expiry dates, serial numbers and supplier references. The receipt becomes the first link in the traceability chain * Material request and issue: operators raise formal requests, store managers release with batch selection, and every issue is attributable to a person, a job and a batch * Returns to store, inter-store transfers and scrap or write-off workflows, each with senior sign-off where required Built for regulated and batch industries: * Batch, lot and expiry tracking with FIFO or FEFO batch suggestion on issue, and pre-expiry alerts at 90, 60 and 30 days, essential for pharma, food and chemicals * Serial number tracking with a full state lifecycle from In Stock to Issued, Returned or Scrapped, forming the join key for end-to-end traceability * Multi unit of measure: purchased in drums, tracked in litres, issued in millilitres, with configurable conversion factors per item and no manual arithmetic for the stores team Control and accuracy: * Replenishment management with near real-time reorder-point alerts, and on-hand versus in-transit clearly demarcated so stock is never double-counted * Physical stock counts with items locked during counting, book quantity hidden during entry to prevent anchoring, and variances requiring senior sign-off before adjustment Supports IATF 16949, 21 CFR Part 11 and ISO 9001 traceability requirements across automotive, pharma and medical devices, chemicals, food and beverage, electronics and energy. Ties into production and inspection on the shared Zometric backbone, so material consumption reconciles against actual production and inspection status gates what can be issued. Browser-based on stores-floor tablets and handhelds. Free pilot configurable in 2 to 3 weeks.

Zometric Production Management

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Zometric Production Management answers the question every plant meeting starts with: are you running to plan, and if not, why exactly? It replaces manual production logs and end-of-shift reconstructions with automated, real-time visibility into every line. Automated capture, real OEE: * Machine cycle data captured automatically via Zometric Edge, including legacy machines through retrofit devices. No manual logging, no data gaps, no end-of-shift reconciliation between paper and reality * Real-time OEE with Availability, Performance and Quality calculated live. Drill down from plant to shift to machine and back up, with the same number and the same definition at every level Downtime that actually gets fixed: * Automatic downtime detection from machine data, with operators attributing causes on tablets * Alerts route in real time to maintenance and supervisors, so recurring losses surface before they become normalised. One customer cut downtime 40 percent without replacing a single machine Plan versus reality: * Job scheduling and planning across machines, tracked against plan with variance alerts as they happen. The schedule on the screen matches the schedule on the floor * Shift and operator tracking links output, quality and downtime to specific shifts and operators. Accountability becomes a data structure, not a confrontation Analytics for improvement: * Throughput trends, cycle-time analysis and line-balancing insights. The continuous improvement team starts with the data they used to spend the first week of every project collecting Aligned with ISO 22400 manufacturing KPI definitions, IATF 16949, ISO 9001 and ISA 95 architecture. Scales from a single line to multi-plant enterprises with consolidated corporate views. Browser-based on any PC, tablet or phone. Free pilot configurable in 2 to 3 weeks with your real factory data.