Case Study: ZPower achieves 1,000× production growth and 360° process visibility with TIBCO Software

ZPower Recharges Production with TIBCO Data Science

ZPower, a pioneer in silver‑zinc rechargeable microbatteries for hearing aids, medical devices, and wearables, needed a unified process control system to scale production dramatically without losing small‑batch quality. The company required end‑to‑end visibility across complex manufacturing steps—over 20,000 data streams—to monitor real‑time sensors and ensure consistent, high‑quality output.

ZPower deployed TIBCO Statistica within the TIBCO Data Science platform to implement flexible, scripted multivariate “multiple stream” control charts and factory dashboards. The solution delivered 360° process visibility, widespread operator dashboards, and real‑time decision support, driving 1,000× higher production capacity, reduced scrap, improved yields and lower costs, and ongoing process optimization.

ZPower

Nitin Arneja

Chief Information Officer