Industry(s): Automotive
Application(s): Structural Components
Processes: Supply Chain Management, Inspection Services
Aerostar Manufacturing in Romulus, MI, USA, prioritizes quality and reliability in its production processes. Our meticulous inspection procedures, from material receipt to final packaging, ensure adherence to stringent quality standards.
Inspection Services
Annual Usage: 36,000
Aerostar Manufacturing, located in Romulus, MI, showcases its unwavering commitment to quality and efficiency. Recently, we embarked on a project focused on the manufacturing of “Bearing Housings”. These components are crucial in various applications, necessitating exceptional precision and reliability. The production lifecycle for this component is meticulously crafted to ensure top-notch quality from raw material receipt to the final product shipment.
Quality Assurance:
Our dedication to quality is evident from the “Receive Material / Receive Inspection” stage. Materials undergo thorough visual inspections to verify correctness, and to ensure there is no damage, contamination, or rust. Post-storage, the materials are machined using Lathe and Mill machines, each tailored with specific tooling configurations and quality control measures.
Quality is ingrained in every phase of our process. Various inspection methods, including attribute gages, variable gages, and Coordinate Measuring Machines (CMM), are employed to examine dimensions, surface finish, and other critical attributes. Our “Zero Defects Allowed” policy highlights the rigor of our quality control measures, where any non-conformities trigger immediate supervisor notification and product isolation for further evaluation.
Product Structure and Data Management:
Our cutting-edge Product Structure by Item Report system, updated as of June 2023, offers a detailed overview of the streamlined manufacturing process for each Bearing Housing unit. This data-driven approach allows us to maintain stringent control over our production lines, optimizing resource allocation while ensuring timely deliveries.
Packaging and Final Inspection:
Adhering to industry standards, the “GP12 Inspection / Pack” stage involves a final visual inspection to ensure correct identification and the absence of visual defects. Each part is carefully packed and prepared for shipping, overseen by our Quality and Engineering Managers to guarantee the highest level of quality.
Conclusion: This project exemplifies Aerostar Manufacturing’s steadfast commitment to delivering products of superior quality and reliability. Our comprehensive evaluation protocols and multi-layered inspection processes make us the ideal manufacturing partner for industries demanding nothing short of excellence.
Project Overview
Quality, Inspection, and Measurement Steps
- Receive Inspection: Ensure the quality of incoming raw materials.
- In-Process Inspection: Monitor and verify quality at each manufacturing step.
- Dimensional Verification: Measure diameters, lengths, and other critical dimensions using gauges and CMM.
- SPC (Statistical Process Control) Data Collection: To evaluate, monitor and control the process (Continuous Improvement).
- Surface Finish Inspection: Check surface finish using profilometers and attribute gauges.
- Thread and Depth Inspection: Inspect threads and depths with attribute gauges.
- Visual Inspection: Identify obvious machining and casting defects visually.
- Barcode Verification: Ensure correct barcode application and readability.
- Final Inspection: Conduct a comprehensive quality check before packaging.
- Packaging Inspection: Verify packaging integrity and adherence to instructions.
- Shipment Verification: Confirm that the product meets customer requirements before shipping.
Equipment and Tools Used for Quality and Inspection Tools
- Variable Gauges: Used for dimensional verification.
- Coordinate Measuring Machine (CMM): For precise measurements.
- Profilometer: For surface finish inspection.
- Attribute Gauges: For inspecting specific features like threads and depths.
- Visual Inspection Tools: Magnifying glasses, lighting, etc.
- Barcode Scanners: For verifying barcode application.
- Barcode Verifiers: To ensure code is marked correctly and meets industry’s quality threshold.
- Calipers: For quick and accurate dimensional checks.
- Go/No-Go Gauges: For specific dimension validation.
- Micrometers: For precise small dimension measurements.
- Inspection Fixtures: Custom setups to hold parts during inspection.
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 Receiving and Storage: Receive and store raw materials appropriately.
- Lathe Machining: Perform turning operations to achieve desired dimensions.
- Milling Operations: Execute milling to create specific features and shapes.
- Drilling: Drill holes to specified dimensions.
- Threading: Create internal or external threads.
- Surface Finishing: Apply surface treatments to achieve required finishes.
- Laser Marking: Apply identification marks such as barcodes using laser etching.
- Lapping: Apply surface treatment to control tight tolerances of flatness, parallelism, and surface finish.
- Deburring: Remove burrs and sharp edges from machined parts.
- Assembly: Assemble components into final product.
- Packaging: Package the finished product according to specifications
Equipment and Tools Used for Manufacturing Steps
- Lathes: For turning operations.
- Mills: For milling operations.
- Drill Presses: For drilling holes.
- Threading Machines: For creating threads.
- Surface Grinders: For surface finishing.
- Laser Etchers: For marking parts.
- Lapping Machine: For surface finishing.
- Deburring Tools: Rotary files, hand deburring tools.
- Fixture Setup Tools: Custom fixtures to hold parts during machining.
- Spot Drills: For creating pilot holes.
- Screw Machines: For automated machining tasks.
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
- Housings
- Bearings
- Casings
- Shafts
- Gears
- Flanges
- Brackets
- Fasteners
- Covers
- Seals
Project Gallery
