Customer Stories
Estoppey-Reber SA

Estoppey-Reber SA Explores the Potential to Digitalize Quality Assurance at Galvanic Production with 1LIMS

Estoppey-Reber SA partnered with 1LIMS to define ways to optimize their quality assurance processes. Through a LabCheck workshop at their Aegerten facility, 1LIMS evaluated Estoppey-Reber's existing methods, focusing on wastewater treatment, controlling the galvanic baths, and QC laboratory. The assessment highlighted reliance on manual processes and the need for digitalization. Key recommendations included implementing a customized LIMS that centralizes all data and integrates with warehouse management software.
Estoppey-Reber SA is a producer of galvanic coatings.
Website
Headquarters
Aegerten, Switzerland
Industry
Mining and metal
Key value delivered
Evaluated existing galvanic production and quality assurance process
Identified risks and digitalization opportunities
Provided recommendations for implementing a centralized LIMS
Dashboard mockup

Business context

Estoppey-Reber SA operates in the field of galvanic coatings. With a rich history and deep expertise, the company excels in providing high-quality metal finishing services. Estoppey-Reber's galvanic coatings improve the appearance, durability, and corrosion resistance of various products, catering to the mining and metals industry.

Seeking to optimize their quality assurance processes, Estoppey-Reber turned to 1LIMS to evaluate how they were controlling the management of the galvanizing baths and identify possible bottlenecks, idle times, and risks.

Our analyzis has shown that Estoppey-Reber could benefit from automation and digitalization. By investing in 1LIMS, they could reduce manual work, minimize errors in analyses, and make data more traceable. We also defined specific functionalities that the company needs in a laboratory information management system to meet its quality control requirements.

Solution overview

We organized a LabCheck workshop, which has provided Estoppey-Reber with an expert evaluation of their quality assurance and control, allowing them to make a confident decision about investing in LIMS.
Key details of the workshop
Objective
Evaluate the existing process in the quality assurance and control laboratory.
Location
The workshop took place at Estoppey-Reber SA's facility in Aegerten, which houses around 200 galvanic baths used for surface finishing.
Duration
1 day

Tour of Estoppey-Reber’s galvanizing process

Optimize quality management processes by reducing manual interventions, eliminating redundant tasks, and automating workflows.
1
Wastewater treatment
Galvanic production involves hazardous chemicals that can harm the environment if not treated properly. Wastewater treatment is the process of removing contaminants from water to make it safe for discharge or reuse.

Estoppey-Reber runs chemical analyses of the wastewater weekly to control dangerous substances, including Nickel, Copper, Chromium, and Cyanide, and ensure compliance with environmental regulations.
2
Galvanic baths
A galvanic bath is a solution used in electroplating to coat metal objects with a thin layer of another metal, enhancing its durability, appearance, and resistance to corrosion.

We observed how samples were collected from the galvanic baths for laboratory analysis, with particular attention to the gold bath, which has stricter regulations and double controls due to its higher costs and quality requirements. We evaluated the in-process control systems, including sensors and live dashboards, which provide real-time monitoring of bath conditions.
3
Quality control laboratory
The quality control laboratory, located within Estoppey-Reber's production facility, plays a crucial role in the galvanic production process. The lab measures the concentration of metals, such as gold, in the baths. If concentrations are out of specification, the lab orders the necessary dosage of metal to be added to the bath. Lab employees also coordinate with logistics to track inventory levels of gold and other chemicals, ensuring timely ordering of new materials when stocks are low or expired. The laboratory communicates the required metal quantities for the baths to production and logistics, ensuring smooth and efficient operations.

Our observations

Estoppey-Reber SA relies heavily on manual processes. Laboratory data is recorded in MS Excel, and record-keeping is done using paper. There is no digital data capture for optical evaluations of the Hull Cell, a method used to test plating baths.
Key metrics
135
reports per week
On average, 135 reports are printed each week
1.10 hours
weekly effort
It takes a lab technician 1 hour and 10 minutes each week to collect all the data and create a report in Excel.
4.5 hours
monthly time expense
The total time spent on data collection and reporting tasks is approximately 4.5 hours per month.
0.5 minutes
report processing time
Processing the reports takes an estimated 0.5 minutes per report.

Challenges identified through SIPOC analysis

Estoppey-Reber SA relies heavily on manual processes. Laboratory data is recorded in MS Excel, and record-keeping is done using paper. There is no digital data capture for optical evaluations of the Hull Cell, a method used to test plating baths.
Paper-only
system
The exclusive use of paper makes it difficult to share, analyze, and retrieve information efficiently.
Data integrity
risks
There is a risk of transmission errors and loss of information.
Redundant
data storage
The exclusive use of paper makes it difficult to share, analyze, and retrieve information efficiently.
Extra data
transition effort
Transitioning between paper and Excel involves additional effort.
Lack of
integration
The lack of integration between different systems leads to inefficiencies, data discrepancies, and a higher likelihood of errors.

Estoppey-Reber's LIMS: Recommended feature set

We advised Estoppey-Reber to integrate the following features into LIMS to overcome the limitations of their manual process.
Centralized data management
Implementing a centralized location for data collection will eliminate the need to transition between paper and Excel, make laboratory analyses accessible to the production department, and ensure traceability of all laboratory information, including production conditions, chemicals used, and dosage amounts.
Standardized analysis plans
Standardized testing processes implemented using integrated test plans will guarantee precision across all assessments and ensure that each test is executed on time. For instance, the system could integrate a maintenance schedule for different chemicals, like carbon treatment, factoring in parameters such as service life and ampere-hours (Ah). Also, with predefined analysis plans and methods, LIMS can help streamline the inspection of incoming chemicals, ensuring quality control from the start.
A photo database
Implementing a photo database for the visual evaluation of the Hull cell will streamline assessment, making it easier to detect patterns or recurring issues in the plating process. It will also enable quick access to historical data, improve traceability, and facilitate training for new staff by providing visual references.
Notifications for OOS analyses
LIMS can automatically generate notifications for missing or out-of-specification (OOS) analyses, enabling quick corrective actions.
Automated risk assessments
By automatically assessing the risks of contaminants in the wastewater or the concentration of the galvanic baths, Estoppey-Reber can improve compliance with safety standards and reduce the impact of unexpected issues.
Roles and permissions
Allowing the company to configure data access permissions ensures controlled access, safeguarding sensitive information and ensuring compliance with regulatory standards at Estoppey-Reber.
Automated calculations
Built-in specified calculations of chemical dosage and quantities will standardize these processes, reducing the likelihood of human error and ensuring precise measurements.
Real-time dashboards
Implementing real-time monitoring of the galvanic baths using a dashboard with control charts and diagrams will provide immediate insights into bath conditions, enabling quick detection and correction of any deviations from optimal parameters.
Integration with a warehouse management system
Connecting laboratory data to the warehouse management software will enable real-time updates on inventory levels, streamline the material ordering process, and reduce the downtime in production.
Interface to external service labs
Establishing an interface to service laboratories for external analyses will streamline data transfer, ensure quicker turnaround times for test results, and improve their accuracy.

Results

The value of implementing 1LIMS
in Estoppey-Reber SA's laboratory

Implementing 1LIMS at Estoppey-Reber will bring the following benefits:
Streamlined laboratory processes
Reduced manual work
Minimized errors in reports
Traceable laboratory activities
Improved data flow between production and laboratory
More accurate analyses
Real-time visibility into QC activities
Consistent quality in galvanic production
Overall, digitalizing the laboratory processes at Estoppey-Reber SA will lead to significant improvements in efficiency, accuracy, and quality, ultimately driving better operational outcomes.

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