Alternator Support

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Aerostar Manufacturing, located in Romulus, MI, continues to uphold its commitment to both precision and quality. Recently, we undertook a project to manufacture Alternator Supports, a critical component used in a variety of applications that demand durability and accuracy.

Aerostar Manufacturing, located in Romulus, MI, continues to uphold its commitment to both precision and quality. Recently, we undertook a project to manufacture Alternator Supports, a critical component used in a variety of applications that demand durability and accuracy. The entire manufacturing process for this part has been carefully developed to ensure consistent quality from the initial receipt of materials to the final shipment of the finished product.

The focus on quality begins at the “Receive Material / Receive Inspection” stage, where incoming materials are visually inspected to verify that the correct product has been received, and to check for any damage, contamination, or rust. Once approved, the material is stored until it moves into the machining phase, where it undergoes milling operations on precision CNC machines.

Throughout the machining process, we integrate rigorous quality assurance protocols. Critical dimensions, milled surfaces, and locations are inspected using attribute gages, variable gages, and Coordinate Measuring Machines (CMM). We also employ pass-through verification for essential characteristics, ensuring that each part meets the stringent standards required. Our “Zero Defects Allowed” approach ensures any non-conforming parts are flagged for further analysis and do not proceed to the next stage without review.

Our advanced manufacturing process is further supported by a comprehensive Product Structure by Item Report system, which is regularly updated to reflect the latest manufacturing details. This system allows us to maintain tight control over production workflows, ensuring that every Alternator Support is produced efficiently and on schedule.

At the final stages, packaging and shipping processes include a “GP12 Inspection / Pack” phase, where the parts are inspected one last time to confirm the correct identification and to eliminate any remaining visual defects. Once passed, the parts are carefully packaged for shipment, with oversight from our Quality and Engineering Managers to ensure adherence to our high standards.

This project exemplifies Aerostar Manufacturing’s dedication to delivering high-quality, reliable components. Our thorough inspection protocols and attention to detail make us a trusted partner for industries that require the utmost in precision and performance.

Project Overview

Quality, Inspection, and Measurement Steps

  • Visual Inspection: Check for correct product, identification, and absence of damage or contamination.
  • Dimensional Inspection: Use attribute and variable gauges to verify critical dimensions and locations.
  • Surface Inspection: Evaluate milled faces for finish quality and detect any surface defects.
  • Pass-Through Verification: Confirm that critical dimensions meet pass-through requirements.
  • Capability Charting: Record significant characteristics for capability analysis.
  • Final Inspection: Ensure product identification and absence of visual defects before packaging and shipping.

Equipment and Tools Used for Quality and Inspection Tools

  • Attribute Gauges
  • Variable Location Gauges
  • Coordinate Measuring Machine (CMM)
  • Visual Inspection Tools (e.g., magnifying glass)
  • Surface Finish Testers
  • Pass-Through Gauges
  • Capability Analysis Software

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

  • Material Receipt and Storage: Receive raw materials and store them under proper conditions.
  • Machining Operations: Perform milling or drilling to achieve required part geometry.
  • Intermediate Inspections: Inspect critical dimensions and locations during the machining process.
  • Fixture Setup: Ensure parts are properly aligned and fixed for consistent machining.
  • Final Machining: Complete milling and finishing operations.
  • Packaging and Labeling: Barcode, pack, and label finished parts for shipment.

Equipment and Tools Used for Manufacturing Steps

  • Milling Machines
  • Drilling Machines
  • CNC Machines
  • Fixture Setup Tools
  • Tool Holders (e.g., PARLEC)
  • Facemills
  • Taps and Drills (e.g., Form Taps, Spot Drills)

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

  • Brackets
  • Alternator Supports
  • Casting Components
  • Milled Faces
  • Drilled Holes
  • Threaded Parts
  • Surface Finishes