Yield Improvement
We lift first pass yield by breaking losses down, investigating root causes and proving each intervention through designed experiments
Yield
Improvement
Our team goes after the gap between the yield you get today, measured first pass, overall and against theoretical, and the maximum your process is capable of. We decompose losses category by category and investigate each one to its root cause. From there we run designed experiments, optimise recipes, intervene on equipment and standardise operator practice, then hold the gains in place through SPC and integrity operating window monitoring so the yield you win does not quietly slip away.
Our implementation model
A practical, phased delivery approach that runs from gap assessment through operational embedding and is built around your regulatory context.
Quantify current yield, first pass, overall, theoretical, by product line, identify yield gaps vs theoretical maximum.
Decompose losses by category, raw material, in process, off spec, rework, scrap, by product handling, Pareto ranking.
Investigate primary loss causes, process variability, equipment performance, control quality, raw material variation, operator practice.
Implement targeted interventions, process control improvement, recipe optimisation, equipment upgrade, operator training.
Statistical validation of yield improvement using hypothesis testing, sustain through SPC and IOW monitoring.
Daily yield reporting, monthly yield focused review, integration with quality and cost improvement programmes.
Yield in full scope
Value of Yield Improvement
- Less reprocessing means less exposure for your people
- Your process runs more stably
- Operators stay engaged in reducing yield loss
- Integrity operating windows stop anyone pushing the plant too hard
- Your yield records are defensible under scrutiny
- You can show food and pharma customers the yield evidence they want
- Your operation aligns with ISA 95
- You hold statistical evidence of capability
- Typically we lift yield by three to ten percent
- You get more throughput from the same input
- Quality improves as the process stabilises
- You unlock headroom in your capacity
- Margin improves directly
- Your material costs fall
- Energy intensity comes down
- You avoid spending capital on new capacity
Codes & standards we work to
Triggers that signal the need
Where Yield Improvement applies
Wellheads, separators, gas compression, FPSO topsides, produced water systems.
Distillation columns, reactors, heat exchangers, storage spheres, LPG handling.
Cryogenic exchangers, liquefaction trains, BOG compressors, storage and sendout.
Reactive systems, batch reactors, solvent handling, runaway reaction scenarios.
Boilers, HRSGs, steam headers, hydrogen systems, ammonia SCR units.
Sterile vessels, CIP/SIP, pressure fermenters, solvent recovery, spray dryers.
Tangible deliverables
- A yield baseline report
- A loss decomposition register
- A root cause investigation
- An intervention design backed by designed experiments
- A statistical validation report
- A sustainment plan tied to integrity operating windows
Ready to start your project?
Speak with our team to scope an engagement tailored to your facility, regulatory context, and lifecycle stage.