The State of Quality Report 2025

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About the Report

Every manufacturer wants to improve quality. But what’s actually happening on the ground floor?

To understand how manufacturers are approaching quality in 2025, we surveyed over 300 professionals in engineering, operations, quality, and manufacturing roles—from operators and managers to decision-makers at global facilities.

Our goal was simple: take the pulse of the industry. Where are teams on their quality journey? How are they tracking key metrics? What tools are making a difference? And what’s standing in the way of progress?

This report is designed to help you benchmark your own quality efforts, uncover opportunities for growth, and kickstart conversations around smarter systems and stronger outcomes.

Here's what we found:

  • outdated
    Nearly every team has KPIs—but many still rely on outdated tools.
  • predictive-img1
    Predictive analytics are gaining attention, but not adoption.
  • training-img1
    Training gaps are holding organizations back from tech-forward change.
  • monitoring-img1
    Real-time monitoring is top of mind—but often out of reach.

The Quality Revolution Has Begun

A movement is underway—and it’s reshaping how quality gets done

Today, quality is no longer just about catching errors. It’s about preventing them. And not just about isolated wins, but scalable, repeatable improvement.

We call this shift the Quality Revolution—and manufacturers everywhere are starting to feel it.

Signs of the shift:

  • Leaders want real-time visibility into quality metrics
  • Teams are rethinking manual and paper-based systems
  • There’s growing urgency around data centralization and faster feedback loops
  • KPIs are defined—but too many are still chasing them reactively

Key Findings at a Glance

Here’s what jumped out from our 2025 survey results:

  • 95% of manufacturers have clear KPIs for quality
  • But only 27% are using real-time monitoring
  • Nearly 1 in 4 teams still rely on paper or spreadsheets
  • 30% use predictive analytics today
  • But 52% want to
  • Data is coming from everywhere, yet only 26% say it’s immediately usable
  • noun-problem-6382680-FFFFFF
    The #1 motivator for quality initiatives? Keeping defect rates stable.
  • noun-disconnected-6347436-FFFFFF
    Most manufacturers want connected systems, but many still work in silos.

This disconnect between aspiration and reality is the core tension shaping the future of quality.

The Tools Powering (and Hindering) Quality Progress

Quality work is evolving—but tools haven’t caught up.

We asked respondents what they use today to manage quality initiatives, SPC programs, and problem-solving projects.

The results showed significant fragmentation:

  • 47% use digital project management platforms (e.g., Asana, Jira)
  • 25% rely on Excel, Word, or SharePoint
  • 24% use internal, custom-built tools
  • 2% still use paper-based methods

Even among the digital adopters, tools often aren’t integrated, automated, or scalable.

Too many teams are doing digital work with analog tools. That’s creating data blind spots, delayed responses, and process inefficiencies that stall real progress.

Where Manufacturers Stand in Their Data Journey

The data is there. But it’s messy, fragmented, and hard to use.

Manufacturers are collecting more data than ever before—but collecting it isn’t the same as leveraging it.

When we asked how teams collect data for quality monitoring, we heard:

54%

rely on operator entry

48%

connect to controllers

36%

use wireless sensors

32%

pull from cloud-connected machinery

Yet despite all this input, only 26% say their data is immediately usable.

Key roadblocks:

  • Data lives in different systems
  • Manual cleaning or combination is required
  • Teams don’t trust the completeness or accuracy of what they’re seeing
  • noun-centralized-6533583-FFFFFF
    The future of manufacturing will be built on connected, clean, and centralized data systems. Many aren’t there yet—but they want to be. 

What’s Fueling the Push Toward Real-Time Quality

Speed, pressure, and the rising cost of being too late.

What’s motivating manufacturers to improve their processes?

  • 36% want to keep defect rates stable
  • 23% must meet quality demands as part of a larger supply chain
  • 17% are actively working to reduce defects
  • 14% are focused on minimizing downtime

Quality teams aren’t just looking for improvement—they’re looking for speed. In an increasingly competitive global market, delayed decisions cost money.

These goals are difficult—if not impossible—to achieve without real-time feedback loops.

  • noun-agile-7219884-FFFFFF
    The shift toward real-time SPC isn’t just about monitoring—it’s about gaining the agility to act before problems grow.

Why the Future of Quality is Predictive

Manufacturers don’t just want to react. They want to anticipate.

We asked teams if they’re using predictive analytics or machine learning in their quality efforts.

  • 30% use predictive analytics today
  • 52% want to—but lack training
  • 12% aren’t leveraging it at all
  • 6% want to—but don’t know where to begin

This tells us something important: the appetite is there. What’s missing is guidance, systems, and support.

Real-world use cases:

  • Forecasting process instability
  • Identifying root causes before issues spread
  • Optimizing production based on historical trends
  • noun-prediction-7755007-FFFFFF
    Predictive analytics can help move manufacturers from “monitoring quality” to actively shaping it.

Unlocking Quality at Scale

You can’t scale quality without solving visibility.

The most advanced quality teams aren’t just making improvements in one plant or one line. They’re building repeatable, scalable systems that work across facilities and teams.

What separates them?

  • Connected dashboards that aggregate data across machines and shifts
  • Alerts that trigger action, not just logging
  • Automations that eliminate manual data entry and reduce variability

We’ve seen that once quality systems become centralized, everything changes:

  • Defects decrease
  • Response times drop
  • Operator trust increases
  • Leaders get clearer ROI visibility
  • noun-repeat-7847405-FFFFFF
    If the tools work for one line—they should work for every line.

Embracing the Revolution: What Comes Next

The Quality Revolution isn't a moment. It's a movement.

The data is clear: teams are ready for better systems, faster insights, and deeper impact.

But readiness isn’t enough. What’s needed now is action—and alignment.

  • noun-foundation-7571599-FFFFFF
    You don’t have to rebuild from scratch. You just need the right foundation.

Here’s what quality leaders should prioritize:

  • Break down data silos
  • Automate data collection wherever possible
  • Invest in centralized platforms
  • Shift from reactive monitoring to proactive decision-making

The Tools Powering (and Hindering) Quality Progress

Quality work is evolving—but tools haven’t caught up.

We asked respondents what they use today to manage quality initiatives, SPC programs, and problem-solving projects.

The results showed significant fragmentation:

0%

47% use digital project management platforms (e.g., Asana, Jira)

0%

25% rely on Excel, Word, or SharePoint

0%

24% use internal, custom-built tools

0%

2% still use paper-based methods

Even among the digital adopters, tools often aren’t integrated, automated, or scalable.

Too many teams are doing digital work with analog tools. That’s creating data blind spots, delayed responses, and process inefficiencies that stall real progress.

Where Manufacturers Stand in Their Data Journey

The data is there. But it’s messy, fragmented, and hard to use.

Manufacturers are collecting more data than ever before—but collecting it isn’t the same as leveraging it.

When we asked how teams collect data for quality monitoring, we heard:

Yet despite all this input, only 26% say their data is immediately usable.

Key roadblocks:

  • Data lives in different systems
  • Manual cleaning or combination is required
  • Teams don’t trust the completeness or accuracy of what they’re seeing

The future of manufacturing will be built on connected, clean, and centralized data systems. Many aren’t there yet—but they want to be.

0%

54% rely on operator entry

0%

36% use wireless sensors

0%

48% connect to controllers

0%

32% pull from cloud-connected machinery

What’s Fueling the Push Toward Real-Time Quality

Speed, pressure, and the rising cost of being too late.

Quality teams aren’t just looking for improvement—they’re looking for speed. In an increasingly competitive global market, delayed decisions cost money.

What’s motivating manufacturers to improve their processes?

0%

36% want to keep defect rates stable

0%

23% must meet quality demands as part of a larger supply chain

0%

17% are actively working to reduce defects

0%

14% are focused on minimizing downtime

These goals are difficult—if not impossible—to achieve without real-time feedback loops.

The shift toward real-time SPC isn’t just about monitoring—it’s about gaining the agility to act before problems grow.

Why the Future of Quality is Predictive

Manufacturers don’t just want to react. They want to anticipate.

We asked teams if they’re using predictive analytics or machine learning in their quality efforts.

  • 30% use predictive analytics today
  • 52% want to use them—but lack training
  • 12% aren’t using them at all
  • 6% want to—but don’t know where to begin
20250429_0218_Predictive Quality Insights_simple_compose_01jsz2ev17fq4adyzwmwppsn8f copy

This tells us something important: the appetite is there. What’s missing is guidance, systems, and support.

Real-world use cases:

  • Forecasting process instability
  • Identifying root causes before issues spread
  • Optimizing production based on historical trends

Predictive analytics can help move manufacturers from “monitoring quality” to actively shaping it.

Unlocking Quality at Scale

You can’t scale quality without solving visibility.

The most advanced quality teams aren’t just making improvements in one plant or one line. They’re building repeatable, scalable systems that work across facilities and teams.

What separates them?

We’ve seen that once quality systems become centralized, everything changes:

Defects Decrease

Response Times Drop

Operator Trust Increases

Leaders Get Clearer ROI Visibility

If the tools work for one line—they should work for every line.

Unlocking Quality at Scale

You can’t scale quality without solving visibility.

multiracial-businesspeople-analysing-company-turno-2025-02-19-15-42-51-utc

The most advanced quality teams aren’t just making improvements in one plant or one line. They’re building repeatable, scalable systems that work across facilities and teams.

What separates them?

What separates them?

  • Connected dashboards that aggregate data across machines and shifts
  • Alerts that trigger action, not just logging
  • Automations that eliminate manual data entry and reduce variability

We’ve seen that once quality systems become centralized, everything changes:

  • Defects decrease
  • Response times drop
  • Operator trust increases
  • Leaders get clearer ROI visibility

If the tools work for one line—they should work for every line.

crop-unrecognizable-female-trader-analyzing-diagra-2025-03-25-10-56-37-utc

Embracing the Revolution: What Comes Next

The Quality Revolution isn’t a moment. It’s a movement.

The data is clear: teams are ready for better systems, faster insights, and deeper impact.

But readiness isn’t enough. What’s needed now is action—and alignment.

Here’s what quality leaders should prioritize:

  • Break down data silos
  • Automate data collection wherever possible
  • Invest in centralized platforms
  • Shift from reactive monitoring to proactive decision-making
You don’t have to rebuild from scratch. You just need the right foundation.

The Solution: Real-Time SPC in Action

Introducing Minitab Real-Time SPC

Take action the moment variation starts—before it becomes a defect. Minitab Real-Time SPC is designed for manufacturers who are serious about continuous improvement. It doesn’t just help you react faster—it helps you build smarter processes from the ground up.

Minitab Real-Time SPC gives you:

  • Live dashboards that monitor every line
  • Automated alerts when control limits are breached
  • A centralized hub for plant-wide visibility
  • Seamless integration with your existing equipment and databases

Perfect for:

  • Reducing waste
  • Meeting supplier quality agreements
  • Minimizing downtime
  • Scaling improvement across sites

It’s not just SPC. It’s visibility, accountability, and improvement—built into every shift.

The Solution: Real-Time SPC in Action

Introducing Minitab Real-Time SPC

Take action the moment variation starts—before it becomes a defect. Minitab Real-Time SPC is designed for manufacturers who are serious about continuous improvement. It doesn’t just help you react faster—it helps you build smarter processes from the ground up.

Minitab Real-Time SPC gives you:

  • Live dashboards that monitor every line
  • Automated alerts when control limits are breached
  • A centralized hub for plant-wide visibility
  • Seamless integration with your existing equipment and databases

Perfect for:

  • Reducing waste
  • Meeting supplier quality agreements
  • Minimizing downtime
  • Scaling improvement across sites

It’s not just SPC. It’s visibility, accountability, and improvement—built into every shift.

Secure Your Spot for Minitab Exchange 2025 Masterclass!

Join our in-person free events focused on digital strategies for optimizing production performance.

Bonus Resources: Videos, Webinars, & More

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ONE PAGER

8 Steps to World Class Quality with Minitab

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BLOG

Why Real-Time SPC is the Key to Seeing & Solving Problems Before They Cost You

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GUIDE

The Key to Predictable, High Quality Manufacturing

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WEBINAR

Expert Insights: Improve Manufacturing Quality with Real Time SPC