Product and process validation

Proven development processes
for reliable results

Product and process validation for customer-specific solutions

At Max Baermann we validate every step of our internal development and manufacturing processes for customer-specific products. From the initial definition of requirements through to final series production, we continuously verify that product, tooling and process meet the agreed specifications.

For product and process validation we rely on years of technical expertise and experienced staff to align the injection molding machine, the mold, the peripherals and the automation precisely with each other. Potential sources of error can thus be identified early and eliminated in a targeted way. In this way we create reliable manufacturing processes that later work perfectly and enable consistently high product quality.

Our services in product and process validation:

Definition and formulation of product specifications
Development and testing of tooling and inspection equipment
Monitoring and corrective action at the start of series production
Analysis, evaluation and documentation of finished products

Pneumatische Greifer einer automatisierten Produktionsanlage zur präzisen Bearbeitung von Bauteilen

Moderne Produktionshalle mit mehreren Spritzgussmaschinen und technischem Equipment

Concept and development phase: validating requirements and product concepts

In the concept and development phase, our specialists translate the customer’s requirements into unambiguous, technically verifiable product specifications. They provide support with …

Defining the requirements in concrete terms: in many projects the desired function, the installation situation or the later ambient conditions are known at the outset, but complete technical specifications are still missing. Together with our customers we identify relevant, realistic characteristic values.
Formulating the specifications: we describe the requirements for the processes and products in such a way that they can be unambiguously evaluated and reliably verified as the project progresses. This creates a solid basis for the subsequent validations within product, tool and process development.
Assessing technical feasibility: finally, we examine whether the planned compound, permanent magnet or plastic component can be realized technically and with process reliability.

Mold sampling: testing product, tooling and processes under near-production conditions

During mold sampling we test and optimize the product, the mold, the inspection equipment and the manufacturing process under conditions that are as close to series production as possible.

Support with mold design: our specialists contribute their experience from process and product validation to the design of the mold at an early stage.
Development of production-ready inspection equipment: in parallel, we support the development and realization of inspection equipment with which the relevant product characteristics can later be checked reliably.
Verification using product prototypes: depending on the complexity of the product, prototypes are used to verify the desired functional, mechanical or magnetic properties at an early stage.
Evaluation using prototype tooling: prototype molds that are as close as possible to production allow the later production process to be simulated and evaluated at an early stage.
Testing of production tooling: completed production tooling is tested in our own technical centre and optimized where necessary.

The insights gained feed directly back into the development process and reduce the need for later adjustments before the start of series production.

Automatisierte Prüfanlage mit Kameras und Sensoren zur Qualitätskontrolle von Bauteilen

Mitarbeiter richtet ein Spritzgusswerkzeug an einer Spritzgussmaschine in der Produktion ein

Transfer to series production: establishing validated manufacturing processes reliably

During the transition to series production, our specialists apply the insights from development and mold sampling to the real production process:

Support during production ramp-up: our specialists support the production start-up and advise the specialist departments involved.
Transfer of validated settings: insights from mold sampling are used to define suitable process parameters for series production.
Alignment of process components: the injection molding machine, mold, peripherals and automation are aligned with one another to create a stable manufacturing sequence.
Early correction of deviations: if disruptions or quality deviations occur during production start-up, they are systematically analysed and specifically resolved.

This creates the conditions for a stable production ramp-up and reproducible manufacturing to the required quality.

Product validation: testing the properties of finished products as required

For finished products we plan, carry out, evaluate and document the required validation tests in close coordination with our customers:

Defining the testing requirements: the type and scope of testing depend on the product, its later field of application and the agreed specifications.
Investigating long-term behaviour: suitable tests show how the product behaves over a defined period and under relevant loads. In this context we also evaluate the mechanical and/or magnetic stability of the product.
Evaluation and documentation of testing: our specialists assess the results and record them in a traceable manner.

Depending on the project, we work either exclusively with our internal test facilities or, where necessary, with external partner laboratories.

Zwei Klimaprüfschränke für Materialprüfungen in einer modernen Laborumgebung

Our other services for the development and production process

Our product and process validation is built on strict internal quality management and is closely interlinked with the various steps of our development and production projects. Find out more about our other expertise here:

Engineering

We develop materials, compounds and magnets tailored precisely to your application and verify their suitability for series production using simulations and prototypes.