Aerostar Manufacturing, a leader in the manufacturing sector, has meticulously streamlined its production process for bearing housing assemblies to uphold the highest quality standards. The components, crafted using a Lathe machine, undergo a series of detailed inspections, covering dimensions, surface finish, and potential defects. These checks are consistent across multiple manufacturing stages, including secondary machining on another Lathe and subsequent milling processes. Leveraging modern Laser Etching technology, Aerostar introduced 2D Data Matrix barcodes for impeccable component traceability. Maintaining strict adherence to ISO standards, the company boasts ISO 9001:2015 and ISO 14001:2015 certifications, showcasing its commitment to quality, customer satisfaction, and environmental sustainability. This unwavering dedication strengthens Aerostar’s reputation as a trusted supplier in the manufacturing world.

Aerostar Manufacturing, a renowned name in the manufacturing industry, implemented a meticulous process to ensure the highest quality production of bearing housing assemblies. This critical component, made using a Lathe machine, undergoes stringent inspections to maintain high standards. Parts storage was done following W15_0002 conditions to guarantee the parts’ optimum condition. The process included comprehensive inspections of significant flatness and diameters using Variable Gages and/or a Coordinate Measuring Machine (CMM). To ensure precision in the dimensions and finish, inspections included diameters, heights, lengths, and surface finish using Variable Gages, CMM, Attribute Gage, and Profilometer. Visual checks were conducted to identify any obvious machining and casting defects.

The process continued with additional machining on a second Lathe, followed by further inspection of diameters, heights, lengths, surface finish, and visual checks for obvious machining and casting defects. Then, the components were moved to a Milling machine for another stage of manufacturing. Again, there was an intensive inspection process. The inspections included significant features, diameters, depths, threads using attribute gages, and surface finish. The positions of these components were evaluated using CMM, and visual inspections were conducted for any apparent machining and casting defects.

Aerostar Manufacturing implemented the latest technology, incorporating Laser Etching for 2D Data Matrix barcodes. This method enhanced traceability, allowing each component to be tracked and identified accurately throughout the process. Final inspections were performed as per instructions before packaging and shipping to customers. Throughout the manufacturing process, Aerostar Manufacturing adhered to international ISO standards. The company is proud to be ISO 9001:2015 certified for Quality Management Systems and ISO 14001:2015 for Environmental Management, signifying its commitment to quality, customer satisfaction, and sustainable practices. These ISO certifications illustrate the company’s dedication to continually improving its products and services, reinforcing its position as a trusted supplier in the manufacturing industry.

Project Overview

Quality, Inspection, and Measurement Tools

  • Material Receipt Inspection: Verify the quality and specifications of the received raw materials.
  • Pre-Machining Inspection: Measure and verify key dimensions and attributes like flatness, diameter, and surface finish.
  • In-Process Inspection: Conduct attribute and variable inspections to verify dimensions, surface finish, and other significant features during machining.
  • Final Inspection & Packaging: Confirm quality, inspect for visual defects, and pack according to guidelines.
  • Barcode Labeling and Storage: Label the finished product with relevant data for tracking and store in specified conditions.
  • Shipping Quality Control: Ensure products meet customer requirements before shipping.
  • Data Collection and Analysis: Log frequencies and use statistical techniques to continuously monitor quality.

Equipment and Tools Used for Quality and Inspection Steps

  • Calipers
  • Coordinate Measuring Machines (CMM)
  • Profilometers
  • Attribute Gages
  • Height Gauges
  • Digital Depth Micrometers
  • Flatness Plates
  • Bore Gauges
  • Runout Gauges
  • Visual Inspection Tools

Quality, inspection, and measurement steps are often closely linked to manufacturing steps. For instance, pre-machining inspections are essential for setting baselines before manufacturing. In-process inspections may pause the manufacturing line for adjustments, thereby ensuring high-quality output. Finally, data collected during these steps can influence future manufacturing decisions.

Manufacturing Steps

  • Material Receiving: Take delivery of raw materials.
  • Material Storage: Safely store materials in a controlled environment.
  • Lathe Operations: Perform turning, facing, and other lathe-based processes.
  • Milling Operations: Conduct planing, drilling, and cutting using milling machines.
  • Deburring: Smooth out edges and remove burrs from the material.
  • Laser Etching: Add barcodes, text, or other relevant data via laser etching.
  • Final Assembly and Packaging: Assemble parts and package the finished product.
  • Shipping: Deliver the finished product to the customer.

Equipment and Tools Used for Manufacturing Steps

  • Lathe Machines
  • Milling Machines
  • Laser Etching Machines
  • Collets and Fixtures
  • Coolant Systems
  • Rotary Files
  • Drills
  • Boring Bars
  • Taps and Dies
  • Cutting Tools (e.g., End Mills, Insert Cutters)

Manufacturing steps often have checkpoints where quality and inspection activities are performed. For example, pre-machining inspections inform what lathe or milling operations need to be carried out. In-process inspections can lead to real-time adjustments in the manufacturing process, ensuring compliance with quality standards.

Manufactured Components and Parts

  • Bearings
  • Housings
  • Shafts
  • Gears
  • Flanges
  • Bolts and Screws
  • Plates
  • Springs
  • Connectors