Johnson Controls MES Implementation: SPC and Scrap Reduction Results

Case studies

MES

Johnson Controls MES Implementation: SPC and Scrap Reduction Results

Case study showing how Epicor Mattec MES enabled real-time SPC, reduced scrap to 1.37%, and improved productivity 8% at an injection molding plant.

Published

June 4, 2026

Read time

3 min read

Source

Johnson Controls implemented Epicor Mattec MES across 44 injection molding machines to automate Statistical Process Control and real-time production monitoring. The system replaced manual data collection with automated queries after 300 cycles, enabling control limit setting for fill times, cycle times, and part dimensions. Results included 23% reduction in start-up scrap, 27% reduction in running scrap, 3.1% less machine downtime, and $600,000 annual cost-of-quality savings.

Key takeaways

Automated SPC after 300 cycles replaced manual data collection across three to four shifts

Scrap rate reduced from 3-4% to 1.37% through daily scrap report reviews and root cause action

Machine downtime decreased 3.1%, productivity increased 8%, conversion cost reduced 13%

Changeover time cut 50% and double-cavity mold cycle time reduced from 54 to 47.5 seconds

Cost-of-quality converted to profit center via reclaim material grinding and external grinding contracts

Market overview

SCR methodology note

Vendor landscape

Leaders

Implementation considerations

Important consideration

Original Source

Vendors mentioned in this report

No items found.