Consumer Packaged Goods · Home & Personal Care

Quality Deviation Detection & Response

Cut time-to-contain from 31 minutes to under 3, tracing the root cause to the upstream machine within 90 seconds.

−91%

Time-to-Contain

From 31-minute average to 3 minutes: Allie detects deviation, identifies upstream cause, and triggers containment before a full pallet is affected

−93%

Quality Hold Volume

Average quality hold inventory reduced from 6,500 units to under 400 units per event

−44%

Customer Complaints

Downstream market complaint rate fell 44% in the 6 months post-deployment across 3 product lines

How Allie Works Here

From signal to action in real time.

Quality ControlProcess ControlProduction Optimization

The Quality Control agent fuses Keyence vision scores, checkweigher Cpk, and date coder verification signals into a unified Quality Index updated every 10 seconds. When the index drops below threshold, the agent traces the deviation signature back through historian tags to the upstream process event that caused it, such as a filler nozzle drip, a cap torque variation, or a label roll splice, within 90 seconds of the first failing unit. The Process Control agent automatically adjusts the upstream parameter and issues a containment boundary: 'hold from unit X to current' with a single confirmation tap from the quality lead.

Machines & Connectivity

OT-connected, protocol-native.

Keyence IV3 Series Vision Sensor

Keyence

EtherNet/IP

100% inline label and cap inspection for 12 quality attributes on each unit at line speed

Mettler-Toledo XS4 Checkweigher

Mettler-Toledo

EtherNet/IP

Dynamic weighing at up to 400 units/min with statistical process control output

Mitsubishi MELSEC iQ-R PLC

Mitsubishi Electric

EtherNet/IP

Line controller integrating vision, checkweigher, and date coder reject gates into unified hold/pass logic

Process Variables

The signals Allie monitors and moves.

Signal Name	Historian Tag	Unit	Baseline	Optimized	Target
Checkweigher Cpk	`QA01.CWH.CPK`	Cpk	0.9–1.3	1.6–2.1	Higher
Label Defect Reject Rate	`QA01.LBL.REJ`	%	0.8–2.1	0.1–0.3	Lower
Time-to-Contain on Quality Alert	`QA01.TTC.MIN`	min	18–45	2–4	Lower
Quality Hold Inventory	`QA01.HOLD.UNITS`	units	4,200–8,800	200–600	Lower

Checkweigher CpkHigher

QA01.CWH.CPK

Baseline: 0.9–1.3 Cpk→ 1.6–2.1 Cpk

Label Defect Reject RateLower

QA01.LBL.REJ

Baseline: 0.8–2.1 %→ 0.1–0.3 %

Time-to-Contain on Quality AlertLower

QA01.TTC.MIN

Baseline: 18–45 min→ 2–4 min

Quality Hold InventoryLower

QA01.HOLD.UNITS

Baseline: 4,200–8,800 units→ 200–600 units

In the Field

"a multi-national HPC manufacturer producing 3 product lines across a single site with strict retail compliance requirements"

Deployed at a multi-national HPC manufacturer producing 3 product lines across a single site with strict retail compliance requirements. The results above reflect production data from the 60–90 day period following full deployment.

−91%time-to-contain

−93%quality hold volume

−44%customer complaints

Next Step

See what your lines are actually capable of.

A 30-minute operational assessment. We review your OT/IT setup, identify the highest-ROI deployment, and deliver a scoped pilot proposal.

Schedule a Plant Assessment