Perfecting Surfaces

We offer you expert and practical support in optimizing and further developing your in-house processes in mechanical, chemical, and electrochemical technologies – both in regular industry and medical device technology. This allows you to focus entirely on your core business.

In operational reality, surface treatment processes are often underestimated – yet they are crucial for the quality and functionality of the final product. Especially in medical device technology, precise surface treatment and cleaning processes are key factors for regulatory compliance and product safety.

Our approach goes beyond simply optimizing the core process.
We also consider all relevant peripheral systems – such as water quality or analytics – and develop a robust, holistic workflow. This ensures stable processes and long-term surface quality.

1. Process monitoring & analytics:

• Monitoring of processes in the laboratory to ensure the desired quality, coating, cleaning, and cleanliness results
• Defining the analysis frequencies and the restart rhythm for the process baths
• Implementation of corrective measures on the process baths in the event of deviations
• Safe handling of chemicals in compliance with personal protective equipment (PPE) requirements
• Use of the “DSLab” laboratory software for digital monitoring support

2. Optimal racking of components:

• Design of racks, frames, and cleaning baskets for process-oriented product arrangement and quality achievement
• Optimal alignment and positioning of components on racks or frames in accordance with the requirements of individual process steps
• Maximization of loading and optimal arrangement to increase process productivity
• Ensuring proper contact during electrochemical processes to prevent visual deviations

3. Peripheral devices:

• Significance and selection of peripheral equipment (e.g., water treatment or exhaust air scrubbers) for process quality and compliance with environmental requirements
• Selection of suitable water types and ensuring defined water qualities to comply with cleanliness and quality requirements

4. Optimal process sequence & process parameters:

• Determination of the optimal process sequence to maximize plant capacity and quality achievement
• Determination of the optimal process sequence to maintain surface quality and the desired cleanliness requirements
• Definition of the optimal process parameters for achieving the desired plant efficiency
• Definition of the optimal process parameters to ensure the required surface quality and cleanliness results

5. MA training (theory & practice):

• Teaching the underlying technologies (e.g., electricity, voltage, CX, or ultrasound) to ensure process effectiveness
• Training in understanding chemical cleaning processes and electrochemical processes (e.g., color anodizing, dark anodizing, and electropolishing)

6. Process validation (PQ):

• Support in implementing product- and customer-specific process validations
• Support in document creation for product- and customer-specific process validations

We support projects in various areas related to production and quality management to meet regulatory requirements and establish stable, efficient processes

1. Quality management in industry and medical technology:

• Implementation and maintenance of QM systems in accordance with ISO 9001 and ISO 13485
• Adaptation and further development of existing QM structures based on internal audits, KPIs, and process indicators
• Interface management between quality assurance, production, and development for comprehensive quality control

2. Conducting process validations: (PQ)

• Planning and implementation of PQ in accordance with regulatory requirements (e.g., MDR, FDA, ISO 13485)
• Creation of valid test plans, documentation, and reports for traceable process approval
• Alignment of the validation strategy with customer requirements and internal risk assessments
• Support for requalification and revalidation in the context of product changes or process adjustments

3. Creating risk analyses:

• Implementation of process FMEA related to electroplating processes
• Identification and prioritization of potential risks using risk priority numbers (RPN)
• Derivation and implementation of appropriate measures for risk minimization and process assurance
• Documentation and continuous updating of risk analyses throughout the life cycle of products and processes

4. Support with error management: (5 Whys, Ishikawa)

• Introduction of a standardized error management process including root cause analysis (e.g., 5-Why, Ishikawa)
• Development of a system of measures for sustainable error prevention and process improvement
• Systematic evaluation of error data to identify recurring weaknesses
• Training teams in dealing with deviations, CAPA processes, and lessons learned

5. Process development & test series

• Development of new process steps or optimization of existing processes in terms of quality, efficiency, and reproducibility
• Design and implementation of structured test series in the laboratory and in production for parameter determination
• Evaluation of test data using statistical methods for decision-making
• Documentation, transfer, and training of the developed processes for series application

6. Interim management:

• Taking over production or department management during transition phases, restructuring, or when positions are vacant

Whether mechanical, chemical, or electrochemical – if you're planning to establish your surface treatment and coating processes in-house, we support you with in-depth experience and practical, hands-on consulting.
With our long-standing expertise in planning, procurement, implementation, and commissioning of surface finishing systems and process solutions in surface technology, we support you every step of the way. Together, we accompany your project – from the initial idea to full-scale production.

1. Needs assessment, goal setting, and regulatory requirements:

• Definition of the components to be processed and planned quantities for the design of the new systems
• Defining process design and workflow structure to ensure efficiency, quality, and flexibility
• Consideration of relevant regulatory requirements and industry-specific standards

2. Layout and space planning:

• Planning the layout of the systems and the process chain to ensure a consistent and efficient process flow
• Integration of existing and planned peripheral devices (e.g., wastewater treatment or exhaust air systems) into room and facility planning

3. Selection of equipment:

• Creation of detailed specifications to clearly define requirements, objectives, and framework conditions
• Preparation of a list of requirements by potential suppliers with specific technical specifications, functions, and performance characteristics

4. Execution & installation of the systems:

• Installation of main systems and process components by the contracted specialist company
• Setup of the associated peripheral systems by the respective supplier
• Carrying out qualification (IQ = Installation Qualification, OQ = Operational Qualification) together with the specialist company for acceptance and qualification of the systems

5. Commissioning of systems and processes

• Filling the systems with the specified process media in accordance with technical specifications
• Conducting initial test runs with rejected parts for functional testing and process control

6. Process introduction & ramp-up support:

• Start of series production in defined production batches for gradual process establishment
• Monitoring product quality and process and plant functionality during the introductory phase

7. Employee training (theory & practice):

• Training of responsible employees in plant operation and process flows
• Integration of relevant peripheral devices and training in process monitoring and control

8. Troubleshooting and process validation

• Analysis and troubleshooting of faults in systems and products during series production
• Support and implementation of process validations in accordance with ISO 13485 and other relevant standards and requirements