Interview
"Instead of replacing machines, we optimize the process using measurement technology."
Experte: André Nowak | 03/10/2025 | Teilen auf in
Stefanie Albrecht is the Managing Director of Promess, a specialist in manufacturing measurement technology based in Berlin. At the INDUSTRIAL FUTURE DAY, she will provide insights into high-precision technologies, analysis methods, and intelligent production systems.
Ms. Albrecht, to achieve improvements in quality and efficiency, companies first need to collect and analyze the right data. How do you support them in this process?
Stefanie Albrecht: With high-precision measurement solutions, we help companies to improve their product quality while minimizing rework and scrap. We master all essential methods for measuring workpieces with tight tolerances. Our particular strength lies in pneumatic methods, which allow us to detect deviations of less than one-thousandth of a millimeter. We develop both the hardware for data acquisition and the software for process control in-house. This enables us to create tailored solutions, from individual measuring stations to fully integrated systems along entire production lines. As a result, our customers can not only produce more efficiently and save resources but also digitalize their manufacturing processes.
We started out in quality assurance for the automotive industry, a sector that has long been a pioneer in this field. Over the past 40 years, we have helped leading manufacturers achieve the highest production standards and have built extensive expertise. Today, we offer testing concepts and solutions for almost any challenge. For example, we can determine the precision of a borehole using a pneumatic measuring probe, inspect complex contours with tactile measuring instruments, or analyze surface properties such as roughness or material cracks using optical methods. We support customers and systems worldwide, including in Romania, South Africa, and India. The specialized knowledge we have gained in the automotive sector is increasingly in demand in other industries, such as medical technology and the food industry.
Could you give us some insight into exemplary projects?
SA: Recently, we optimized engine manufacturing for a major Indian commercial vehicle manufacturer. The engines in question feature blocks with up to ten liters of displacement. A critical quality factor is ensuring that the valves operate smoothly within their seats and create an optimal seal with the combustion chamber. Even the slightest deviations in manufacturing can lead to wear, malfunctions, and customer complaints. The client required more precise, integrated measurement technology to remain competitive not only in their domestic market but also on a global scale.
We set up a test system and discovered that the left-side valve seats were manufactured slightly differently from the right-side ones. As a result, the energy output was lower, and wear was higher on one side of the engine block. Such an engine would not last long, posed a safety risk, and consumed unnecessary resources. Thanks to our measurement systems, the client was able to permanently eliminate these defects, significantly improving quality and customer satisfaction.
For a medical technology manufacturer, we helped measure portioning devices for pharmaceutical production and stamping instruments for tablet manufacturing. In the latter case, powdered substances are compressed. If the pressing elements do not align precisely, material can escape, leading to losses and disturbances in the process that jeopardize the compression. In some cases, entire batches had to be discarded. Our solutions enabled the company to ensure a flawless and efficient production process.
Which trends in production do you find particularly exciting, and how can companies keep up with rapid developments?
SA: Increasingly networked measurement processes and automation are clearly moving toward autonomous production. Throughout the entire production chain, machines will communicate more with each other and coordinate their operations. For example, if one machine produces components that are slightly oversized, the next unit can receive this information in real time and adjust accordingly. Using modern interfaces like OPC UA, such data can also be synchronized with higher-level ERP systems. These intelligent systems provide companies with deeper insights into their manufacturing processes, allowing them to detect trends early and implement optimizations.
Many companies are unaware that such precise and intelligent manufacturing is possible even on a limited budget. Many medium-sized businesses operate machines that are over 20 years old, leading to decreasing production accuracy. However, investing in new equipment is not always necessary. Our measurement technology can be flexibly integrated into existing machines, detecting even the smallest deviations. Instead of replacing the machine, we optimize the process. The machine learns how to produce in order to achieve the desired results. This downstream quality assurance can extend the service life of machines by several years.
Can you give us a brief preview of your presentation at the INDUSTRIAL FUTURE DAY 2025? What can participants expect?
SA: We will demonstrate how our measurement solutions significantly enhance quality and efficiency in production. Using a specific component, we will show how our measurement methods can detect and quantify the smallest deviations. Secondly, we will illustrate how this data is used to adjust production processes and ensure continuous product quality. Finally, I will provide an outlook on the future of measurement technology in the context of Industry 4.0, including statistical process control and integration with higher-level systems.
