Reduce scrap
Industrial challenge
Improving an unstable process
Understand the causes of process drift to improve long-term production reliability.
Explore our expertise
The context and
your challenges
An unstable process can cause defects, quality variations and production losses. Identifying the cause of drift requires analysis of the entire system: materials, process parameters, the environment and their interactions.
Your needs
Industrial realities
Improve process repeatability
Limit production downtime
Identify critical parameters
Improve industrial robustness
Our approach
The approach at Filab Genium
Filab Genium supports every part of the value chain in selecting and securing raw materials so they never hold back your development. Using materials databases, close supplier relationships and in-depth knowledge of materials and chemistry, we can quickly identify suitable options for your needs.
01
Defining requirements
What operational performance do you expect from your product? How do you use it? Our teams can examine and refine these requirements during a site visit.
02
Translating requirements into material specifications
Based on your needs, our teams establish a specification for physicochemical properties, weighted according to the importance of each function.
03
Material search & comparison
Using materials databases and our supplier relationships, we provide a list of materials objectively ranked and scored against your specifications.
04
Experimental validation
Laboratory-scale testing and support with industrial scale-up.
Know-how
Expertise brought together
Process audit
Materials analysis
Chemical characterisation
On-site investigation
Specialist testing
our key strength
Validation through evidence
The hypotheses identified can be confirmed through analysis and experimentation to validate corrective measures.
Business value
Customer benefits
Reduce defects
Improve production reliability
Improve industrial performance
Customer case study
Reducing scrap
A manufacturer was experiencing a high rate of non-conformities with no obvious explanation.
An approach combining on-site assessment, scientific investigation and analytical validation identified several opportunities for improvement.
Is your process unstable?
Our consultants help you identify the causes and develop solutions.
Frequently asked questions
Find answers to the questions our industrial customers ask most often. Have a question about your project? Our experts will respond within 24 hours.
By combining production-data analysis, on-site observation and material characterisation to rank the factors involved.
Stabilising an industrial process
An unstable process leads to variable quality, scrap and production downtime. Stabilisation requires identification of critical parameters and control of their variability.
Material variability and process drift
Raw-material variability is a common cause of instability. Characterising it helps adjust process parameters or strengthen purchasing specifications.
Process auditing and on-site investigation
Direct observation of operations often reveals differences between actual practice and written procedures that cause recurring drift.
Industrial robustness
A robust process tolerates normal variations in its environment. Improving this robustness delivers lasting reductions in non-conformity costs.