Consultancy
Research & Development
“Blue Tesseract delivers solutions tailored to your organisation’s unique challenges — solving root causes and building lasting improvements in quality and reliability.”
Let's collaborate - this is what we do
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Root-Cause & Quality Improvement – Apply structured problem-solving and corrective action planning to eliminate recurring issues and improve process stability. Techniques such as 8D, DMAIC/DMADV, PDCA, FMEA, and SPC are tailored to each client’s needs, ensuring lasting reliability gains.
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Pilot Line Design & Scale-Up – We support the transition from lab to production by specifying equipment, process flows, safety, and QA checkpoints. Commission and stabilise pilot runs to de-risk investment and accelerate scale-up.
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Materials & Process Optimisation – Design statistically robust experiments and optimise parameters for performance, yield, and capability (Cp/Cpk). DOE and RSM approaches reduce wasted trials while enhancing insight quality.
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Technology Transfer & Industrialisation – Translate laboratory results into manufacturing workflows. Develop SOPs, validation protocols (IQ/OQ/PQ), and training packages to ensure successful industrial adoption.
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AI-Enabled Diagnostics & Reliability – Implement predictive analytics and anomaly detection to anticipate failures, reduce downtime, and improve asset reliability. AI-driven dashboards link sensor data to actionable insights.
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Independent Technical Review & Cost/Benefit Analysis – We provide impartial second-opinion reviews, feasibility studies, and cost–benefit assessments to guide strategic investment and mitigate risk.
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Technical Documentation & Communication – We deliver clear, professional technical outputs — including reports, feasibility studies, design reviews, funding applications, investor decks, and academic-style publications — ensuring decisions are well-supported and stakeholders aligned.
“Every innovation journey is different; we guide yours from lab to production with a scale-up pathway designed around your needs.”
Key benefits:
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Solve Root Causes, Not Symptoms – Tailored problem-solving strengthens reliability and reduces recurring defects. Peer-reviewed studies revealed DMAIC frameworks reduced defect rates from 5.5% to 3.1% and stabilised process variation in manufacturing settings [1]
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Accelerate Scale-Up from Lab to Production – Structured pilot-line development lowers uncertainty when moving innovations into production. Research in advanced materials scale-up showed that applying systematic pilot design cut failure probability and improved investment outcomes compared with ad-hoc approaches [2]
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Optimise R&D Investment Efficiency – Smarter experimentation through DOE and AI-enabled optimisation reduces trial numbers and resource use. Studies confirm fractional factorial DOE can reduce experimental runs by 50% while still identifying critical process variables [3]
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Reduce Downtime with Predictive Diagnostics – AI-driven monitoring enables proactive maintenance and improved operational continuity e.g. 2025 automotive sector predictive models achieved ~80% accuracy in forecasting failure cycles, significantly reducing unplanned stoppages [4]
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Strengthen Decision-Making with Evidence-Based Reviews – Independent technical assessments guide investment with impartial clarity. FMEA-based reviews lower Risk Priority Numbers (RPN) by more than 50% after corrective measures, directly reducing risk exposure [5]
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Communicate Clearly Across Stakeholders – Professional technical reporting ensures clarity for engineers, managers, and investors. Studies reveal structured technical communication improved stakeholder alignment and accelerated decision-making by 30% in engineering projects [6]
References:
[1] Condé, G. et al. (2023). Defect Reduction using DMAIC and Lean Six Sigma: a case study in a manufacturing car parts supplier. Federal University of São Carlos.
[2] Kamal, R. et al. (2022). Scale-up challenges in advanced materials: pilot plant development and risk mitigation. Journal of Manufacturing Processes.
[3] Feldman, K. (2024). Exploring the Benefits of Fractional Factorial DOE. iSixSigma.
[4] Ojeda, J.C.O. et al. (2025). Application of a Predictive Model to Reduce Unplanned Downtime in Automotive Industry Production Processes. Sustainability, 17(9), 3926.
[5] Lee, J. et al. (2017). FMEA-based risk reduction and RPN improvements in industrial workflows. Risk Analysis, 31(1).
[6] Al-Khatib, H. et al. (2023). Improving technical communication for engineering projects: impact on stakeholder decision-making. International Journal of Project Organisation and Management.
“Blue Tesseract combines structured methods and AI-enabled tools with bespoke analysis, so your R&D investments deliver faster, clearer answers.”
Reasons why you'll love collaborating with us...
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Tailored, Evidence-Based Solutions – Every engagement is designed around your industry, scale, and goals, supported by peer-reviewed methods and proven industrial results — not generic templates.
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Scientific Depth with Business Outcomes – PhD-level technical expertise is combined with structured methodologies (e.g. 8D, DOE, FMEA) to drive measurable improvements in cost, quality, and time-to-market.
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AI-Enhanced R&D Delivery – Integration of AI for predictive diagnostics, process optimisation, and decision support provides clients with cutting-edge tools that reduce uncertainty and accelerate results.
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Full Lifecycle Support – From problem analysis to pilot-line design, scale-up, technology transfer, and documentation, we can deliver end-to-end R&D support.
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Independent and Impartial – External, objective reviews ensure clarity, uncover blind spots, and guide investment with confidence.
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Cross-Border Capability – Deep experience across the UK and China ecosystems enables clients to establish partnerships, navigate compliance, and align technical standards across markets.
Service payment model options
Start with a free no obligation consultation to quickly assess your needs
Service payment options are then tailored to your needs based on the service(s) you use. Common options include: Hourly Rate (or per word for editing/proofreading), Flat Project or report Fee, Retainer Model, Milestone Payments, Performance-Based, Equity-Based, or Hybrid Model.
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