Case Study: Gallo Glass Company achieves $5M/year savings, 5% production increase and 25% reductions in defects and downtime with Northwest Analytics

Gallo Glass uses Quality Analytics and Reporting tools from NWA for World Class Production

Gallo Glass Company, one of the world’s largest bottle plants in Modesto, CA, needed a high-performance process quality management system to monitor hundreds of production parameters and deliver role-specific SPC and manufacturing analytics across 14 glass lines producing over 2 million bottles a day. They selected Northwest Analytics’ quality analytics and reporting tools—including NWA Quality Analyst and QAx ActiveX components—embedded within a Shop Floor Information System built on GE Fanuc iFIX and MS SQL to support continuous process improvement.

Northwest Analytics’ software was integrated into the SFIS to provide real-time operator displays, automated SPC and process-improvement reports, and KPI tracking (over 1,600 variables and metrics like Percent Pack) for engineering and management. The solution produced measurable results: $5 million/year in savings, a 5% increase in production, 25% fewer defects, 25% reduction in downtime, faster training, and improved operator performance, enabling broader Lean/Six Sigma and enterprise manufacturing analytics.

Gallo Glass Company

John Gallo

VP