In high-reliability industries like aerospace and defense, the margin for error is razor-thin. A single test failure can stall production, trigger rework, and create uncertainty across the entire supply chain. Yet in many cases, the root cause behind these failures isn’t immediately clear.
That’s exactly why Omega Research developed Variable Elimination Testing (V.E.T.). We saw a pattern: customers were repeatedly facing nonconformances with no obvious explanation, often resorting to trial-and-error or full process overhauls to chase down the issue. V.E.T. was created to address that challenge directly, with a structured, data-driven approach designed to isolate and eliminate the unknowns.
Built into the culture of Omega is a desire to reduce failure rates, not just test for them. V.E.T. reflects that mindset. It’s not a substitute for process control but a tool to reinforce it. The methodology follows the Plan-Do-Check-Act cycle required under AS9100, offering manufacturers a framework to investigate failures systematically, support test invalidation when appropriate, and make precise process adjustments that lead to more consistent results.
Turning Failures Into Actionable Insight
Unlike standard lab tests that simply confirm pass/fail, V.E.T. is a methodical investigation. It isolates process variables one by one, things like bath chemistry, post-treatment time, cure conditions, or substrate variability, to determine exactly what’s causing the issue. By identifying the root cause, manufacturers can make focused corrections instead of overhauling their entire process.
A Problem-Solving Tool That Supports AS9100
Aerospace and defense manufacturers operate under the rigorous AS9100 quality standard. That standard emphasizes data-driven decision-making, process validation, and continuous improvement.
V.E.T. aligns directly with the Plan-Do-Check-Act (PDCA) cycle at the heart of AS9100:
- Plan: Evaluate potential variables that could be impacting test outcomes.
- Do: Run comparative tests on controlled samples.
- Check: Analyze results to identify trends and failure points.
- Act: Apply findings to correct the root cause, then retest to confirm.
Whether you’re working through a corrective action request or building a stronger case for test invalidation, V.E.T. gives you the evidence and insight you need.
Real-World Testing Scenarios
V.E.T. is tailored to the test, the failure, and the process in question. Here are a few recent applications:
Hydrogen Embrittlement Testing (ASTM F519): After a failure, we helped a customer pinpoint excess hydrogen introduced by a mis-calibrated acid clean. Testing revealed the right bake time—375°F ± 25°F for 23+ hours—leading to a successful retest.
Salt Spray Testing (ASTM B117): A customer saw early corrosion failures in parts that should have passed. V.E.T. uncovered the culprit: a rinse stage using contaminated water. Once replaced with DI water, results improved immediately.
Coating Weight Testing (MIL-PRF-8625): An inconsistent phosphate coating led to rejected parts. Through immersion time and bath concentration testing, V.E.T. helped the customer refine their chemistry and hit consistent coating weight targets.
Taber Abrasion Testing (ASTM D4060): A batch of parts failed due to premature wear. Investigation revealed under-curing as the issue. Adjustments to cure temperature and humidity eliminated the problem.
Why Manufacturers Choose Omega’s V.E.T. Program
When production is on the line, companies turn to Omega not just for lab services, but for partnership. We’ve been helping aerospace manufacturers troubleshoot process control failures for over 40 years. That experience informs how we design V.E.T. programs—from custom test matrices to side-by-side comparisons—always backed by NADCAP-compliant documentation and detailed data reports.
Our V.E.T. services are priced at approximately 50% of standard test cost, and there are no minimums. We also offer “Information Only” reports that provide insight without triggering formal nonconformance documentation. With Variable Elimination Testing from Omega Research, you can move quickly from confusion to clarity…and from failures to fixes. Want to learn how V.E.T. can support your production, QA, or R&D goals? Contact us today, or call 940-648-5828 to speak with a member of our team.
