Case Study: Fastco Industries achieves lower Cost of Poor Quality and real-time SPC control with Zontec’s Synergy 2000

Fastco Industries - Customer Case Study

Fastco Industries, a Michigan-based manufacturer of special fasteners, faced a drop in quality performance after a decade of holding a Cost of Poor Quality (CoPQ) target of 0.4% of sales and needed a cultural and leadership shift to regain control. To address this, Fastco implemented Zontec’s Synergy 2000 SPC software to replace an outdated paper-based system and support its commitment to zero defects and on-time delivery.

Zontec’s Synergy 2000 delivered real-time SPC, operator alerts, flexible reporting and integration with the Keyence Vision System, allowing Fastco to standardize measurements, identify training needs and reduce operator-to-gage variation. As a result (and after management changes), Fastco met its CoPQ metric again and lowered CoPQ from 0.40% to 0.37% in 2013, and pursued a 0.35% goal in 2014 (met 6 of 8 months), while gaining faster dimensional reporting and improved process visibility thanks to Zontec.

Fastco Industries

Brian Kropp

Quality Control Manager