At Omega, we do more than just deliver test results. We partner with customers to uncover the root cause of failures and develop lasting fixes. When encountering repeated failures , we use our Variable Elimination Testing (VET) program, a systematic approach that eliminates process variables and fine-tunes plating reliability. VET supports manufacturers in their own CAPA processes, helping them meet industry requirements while ensuring long-term process stability.
Why Do Tests Fail?
Understanding why a test fails is the first step to preventing it from happening again. Some of the most common culprits include hydrogen embrittlement. Traditionally, hydrogen embrittlement was thought to require large amounts of hydrogen. However, studies have shown that even tiny amountscan cause failure. Hydrogen accumulates in areas of high stress within the metal, leading to microcracks that rapidly grow, weakening the metal’s structure.
Plating adhesion issues are another common cause, where coatings fail to bond properly due to surface contamination or process deviations. Material inconsistencies or defects can also contribute to failures, as certain substrates may react unpredictably to plating and coating processes. Additionally, deviations in heat treatment, plating, or coating application can lead to unexpected outcomes that compromise the final product.
Without a thorough investigation, the same problem may continue to arise, leading to ongoing production setbacks and increased costs.
What Happens After a Test Failure?
Omega developed a structured approach to diagnosing and resolving failed tests without the runaround.
When a test fails, you’ll speak directly with one of Omega’s experts. We take the time to gather key details about your part specifications, plating methods, and test conditions. This helps us quickly identify where things might have gone wrong.
Our team takes a deep dive into the test data, analyzing process records, historical trends, and prior results to determine whether the failure was a one-time issue or part of a larger pattern.
Once we understand the root cause, we work with you to develop a fix. That could mean adjusting plating chemistry, tweaking baking cycles, or leveraging our VET program for repeated failures to systematically eliminate process variables and ensure a robust CAPA strategy.
VET was designed to address and eliminate the variables that arise during the plating process. It allows for real-time monitoring and data collection, enabling us to gather critical information from each machine as it operates. The key advantage of this system is that it provides an immediate and clear overview of the entire operation on a single dashboard.
Omega’s Experts Help You Find the Fix
A failed test doesn’t have to bring production to a halt. With Omega’s expertise and problem-solving approach, we help manufacturers not only understand why a failure happened but also implement real solutions that prevent it from happening again. By combining our VET programwith hands-on customer support, we help businesses optimize their plating processes, improve reliability, and reduce future failures. Reach out to Omega today and let’s get your process back on track.
I think it’s more than that. I believe that they electroplate a batch of products and the testing sample at the same time. If the testing sample fails, the entire batch of the product that was electroplated (the electroplater’s customer’s product) is list and has to be replaced to redo the process. Please check with Robert that it is indeed the case.
