A complete walkthrough of every phase — how configuration leads to data collection, how data collection drives analysis, and how analysis produces the quality documents your customers and auditors require.
ERGOSTASIO replaces the patchwork of spreadsheets, manual certificates, and disconnected tools that most manufacturing plants rely on. Every data point entered once — tracked, analyzed, and reported automatically from that point forward.
Define every process parameter you want to track — temperature, viscosity, yield, pH, whatever your process requires. Each variable gets a name, unit, data type, and optional library lookup.
Bind datasets to data entry screens. Each screen defines the input form that operators will see. Seven screen types cover all common process data collection scenarios — from batch records to continuous monitoring.
Set control limits for SPC (UCL, LCL, warning bands) and specification limits for compliance checking (LSL, USL). Product specs define what ships. Customer specs customize the COA per recipient.
Create users and assign roles. The Admin controls who can access which modules. Operators see data entry. Builders see configuration. Each module — COA, ATU, SPC, MSPC, Rounds, Drift Twin — can be enabled or disabled per plant.
Operators navigate to their assigned screen, enter readings for each variable, and submit. ERGOSTASIO validates every value in real time — spec breaches are highlighted immediately, and supervisors are alerted before the operator leaves the screen.
An outgoing shipment is logged by selecting the product group, product, and customer. ERGOSTASIO routes to the correct COA configuration and opens the certificate wizard. Data already in the system populates automatically — the operator fills only what's new.
An incoming material lot is logged by selecting material group, material, and vendor. ERGOSTASIO opens the ATU test entry form — a mirror of the COA workflow but for raw materials. Each lot gets a serial number and full test record.
Ad hoc samples are checked in and assigned to a dataset for analysis. The request is tracked through the lab — logged, analyzed, and reported. Nothing is lost in email or on paper. Every result is traceable to an operator and a timestamp.
Xbar-R and I-MR charts are maintained automatically for every variable with control limits defined. Each chart plots the last N readings, shows the centerline and control limits, and highlights any point or pattern that violates Nelson rules.
Four compliance tiers, evaluated the moment a reading is submitted. ERGOSTASIO doesn't wait for a report to run — the alarm fires at entry time, before the operator moves on to the next task.
Structured shift walks defined in the Builder as round templates with per-item instructions. Operators execute rounds on-screen, logging each item as they go. Shift, start time, and completion status captured automatically.
Every entry is compared against the product specification for that variable. Compliance is tracked as a percentage across a date range or batch. QA managers can pull a compliance snapshot for any product, dataset, or time period instantly.
PCA-based Hotelling T² and SPE (Q) statistics monitor all process variables simultaneously. A single MSPC score captures cross-variable correlations that univariate charts can never see — an early warning when the process starts to drift as a system, not just one variable at a time.
Capture a baseline mean and σ for every process variable from a known-good period. The Drift Twin then continuously compares the rolling live window against that baseline and surfaces per-variable drift scores in σ units — so slow, gradual shifts are caught before they breach a hard limit.
Ask plain-language questions about your plant in the Athina AI assistant. The system retrieves the most relevant passages from your ingested documents — SOPs, manuals, alarm procedures, MSPC guides — and passes them as context to Claude (Anthropic). Answers are grounded in your own plant knowledge, cited with source and similarity score.
Choose from configured product lines. The shipment is registered.
Customer spec overrides applied automatically for this recipient.
Routing rules map product + customer to the correct template.
Lot number, batch ID, dates, production line. Auto-filled where possible.
Test results entered against the template variables. Spec compliance shown inline.
QA manager reviews. Status: draft → pending_auth → authorized → issued.
Certificate issued. PDF emailed directly to customer. Audit log updated.
Choose from configured material lines. The receipt is registered.
Vendor record linked. Vendor spec profile loaded automatically.
Routing maps material + vendor to the correct ATU template.
Serial number, lot, order, invoice, dates. Full traceability captured.
Test values entered per ATU template variables. Vendor limits checked inline.
QA reviews. Status: draft → in_progress → pending_review → issued / rejected.
Report issued. Lot accepted or rejected. Vendor history updated. Audit log complete.
ERGOSTASIO is configured by your own engineers using the Builder. No external consultants, no IT project, no six-month implementation. A QA engineer who knows your process can have the system collecting data, generating charts, and issuing certificates within a single working day.
Open the DemoConfiguration is done through guided forms by your QA engineers.
Demo environment is fully loaded. Your own setup starts the same day.
Nothing to install on the plant floor. Tablets, desktops, any device.
Add variables, redesign screens, update specs — no code, no downtime.
Every entry, every change, every issued certificate — timestamped and attributed.