Air Intake Adapter

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Aerostar Manufacturing, based in Romulus, MI, meticulously crafts Air Inlet Adapters, ensuring unparalleled quality from raw material inspection to final product shipment. Their commitment to excellence, evident in rigorous quality control measures and state-of-the-art manufacturing processes, makes them a trusted partner for industries demanding precision and reliability.

Aerostar Manufacturing, located in Romulus, MI, is steadfast in its dedication to both quality and efficiency. In recent times, we embarked on a project focused on the manufacturing of Air Inlet Adapters. These components are pivotal in various applications, requiring a high degree of precision and reliability. The manufacturing lifecycle for this part has been meticulously crafted to ensure unparalleled quality from the moment the raw material arrives to the final shipment of the finished product.

Our commitment to quality is evident right from the “Receive Material / Receive Inspection” stage. At this juncture, materials are visually inspected to confirm the correct product has been received, and to ensure there is no damage, contamination, or rust. After storing the material, it undergoes machining processes involving Lathe and Mill machines, each with its specific set of tooling configurations and quality control measures.

Quality assurance is not just a step in the process; it’s integrated into every phase. Various inspection methods, such as attribute gages, variable gages, and Coordinate Measuring Machines (CMM), are employed to scrutinize dimensions, surface finish, and other critical attributes of the part. Our “Zero Defects Allowed” policy underscores the rigor of our quality control measures. Any non-conformities trigger immediate supervisor notification and isolation of the product for further evaluation.

Our state-of-the-art Product Structure by Item Report system, updated as of June 2023, provides a comprehensive overview of the streamlined manufacturing process for each Air Inlet Adapter unit. This data-centric approach enables us to maintain stringent controls over our production lines, optimizing resource allocation while ensuring punctual deliveries.

When it comes to packaging, we adhere to industry standards. The “GP12 Inspection / Pack” stage involves a final visual inspection to ensure correct identification and absence of visual defects. Each part is then carefully packed and prepared for shipping, overseen by our Quality and Engineering Managers to guarantee the highest level of quality.

This project serves as a testament to Aerostar Manufacturing’s unwavering commitment to delivering products of the highest quality and reliability. Our exhaustive evaluation protocols and multi-layered inspection processes make us an ideal manufacturing partner for industries that demand nothing less than excellence.

Project Overview

Quality, Inspection, and Measurement Steps

  • Initial Material Inspection: Verify the integrity and specifications of incoming materials.
  • Visual Inspection: Check for visible defects, damage, or contamination.
  • Dimensional Inspection: Measure dimensions using appropriate tools to ensure they meet specifications.
  • Functional Testing: Test the functionality of components or assemblies.
  • Packaging Inspection: Ensure correct and secure packaging.
  • Final Audit: Conduct a comprehensive review of the product and its documentation.
  • Shipping Inspection: Verify the correct product, quantity, and identification before shipping.
  • Customer Feedback: Collect and analyze customer feedback for quality improvement.

Equipment and Tools Used for Quality and Inspection Tools

  • Visual inspection tools (e.g., magnifying glasses, shadowgraphs).
  • Dimensional measurement tools (e.g., CMM, micrometers, depth gauges).
  • Surface finish measurement instruments (e.g., surface roughness testers).
  • Gaging tools (e.g., go/no-go gage pins).
  • Inspection tags and documentation forms

These steps often intertwine with manufacturing steps to ensure a feedback loop exists between the production process and quality controls. Discrepancies detected during quality checks can lead to modifications in the manufacturing steps.

Manufacturing Steps

  • Install equipment such as chucks and hydraulic cylinders with proper hardware.
  • Set parameters and chuck pressure according to specifications.
  • Load parts onto fixtures or workholding devices.
  • Use CNC programs and tool sequences to perform machining operations.
  • Conduct setup procedures, including aligning parts and verifying proper clamping.

Equipment and Tools Used for Manufacturing Steps

  • Maxi Grip chuck and hydraulic cylinders.
  • Torque wrenches for tightening screws.
  • CNC machines and lathe centers.
  • Tool holders and cutting inserts.
  • Workholding devices such as fixtures and tailstocks.

The steps in manufacturing are often revisited based on the results of the quality checks. For example, if an intermediate inspection detects an issue, the material may go back to the assembly stage.

Manufactured Components and Parts

  • Air intake connection (multiple variations).
  • Various machined features such as grooves, bores, and faces.
  • Chuck components and grippers.
  • Casting and machined parts.
  • Workholding fixtures and supports