Belt Tensioner Bracket

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Aerostar Manufacturing, located in Romulus, MI, demonstrates its dedication to precision and reliability through a meticulous project focused on manufacturing Belt Tensioner Brackets. This project integrates stringent material inspection, advanced machining, and thorough quality controls to ensure the delivery of high-quality components.


Aerostar Manufacturing, located in Romulus, MI, is undertaking a manufacturing project with a primary focus on producing Belt Tensioner Brackets. This project demands a meticulous manufacturing and quality control process to guarantee the delivery of top-tier components.

The manufacturing process commences with a comprehensive receiving inspection, during which all components undergo visual scrutiny for correctness, damage, contamination, and rust. Materials are stored as needed. Subsequently, the components are subjected to machining operations, specifically through Milling Machines A & B. These operations include the inspection of various attributes, such as diameters, ports, threads, milled faces, and locations, employing attribute gages, variable gages, and coordinate measuring machines (CMM). Additionally, the components are visually inspected for surface finish and any visual defects. Once again, materials are stored as required.

The interdependence of manufacturing and quality control processes becomes apparent as the manufacturing steps align closely with quality inspection procedures. After machining, the components undergo another visual inspection to verify correctness, proper identification, absence of damage, and contaminants before they proceed to the packing stage. During packing, a visual examination is carried out to ensure the suitability of packing materials and dunnage, along with detecting any apparent machining and casting defects. A final audit is conducted to confirm the correct identification and the absence of visual defects.

Engineers at Aerostar Manufacturing rely on an array of specialized equipment and tools throughout these processes. This includes milling machines, diamond facemills, carbide drills, high helix carbide endmills, carbide spot drills, form taps, collet holders, shrink-fit holders, sanding disks, and deburring tools. The precise utilization of these tools and equipment is pivotal in achieving the desired levels of precision and maintaining quality standards.

This comprehensive approach underlines Aerostar Manufacturing’s unwavering commitment to the production of components that meet stringent quality and reliability criteria. Engineers closely involved in this project play a pivotal role in overseeing and optimizing these manufacturing and quality control processes to ensure the Belt Tensioner Brackets meet the highest industry standards.

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

  • Variable Gages
  • Coordinate Measuring Machine (CMM)
  • Attribute Gages
  • Visual Inspection Tools

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 Preparation: Sort and prepare raw materials for manufacturing.
  • Setup: Configure machinery and tools for the specific manufacturing process.
  • Primary Machining: Perform initial cutting, milling, or shaping operations.
  • Secondary Operations: Perform additional processes like drilling, chamfering, or deburring.
  • Assembly: Assemble various components into a complete unit.
  • Quality Control: Implement quality checks and corrections.
  • Packaging: Pack the final product for shipping or storage.
  • Shipping: Prepare and send the product to the customer or next stage in the supply chain.

Equipment and Tools Used for Manufacturing Steps

  • Milling machines (Mill A & B)
  • Diamond Facemill
  • Carbide drills
  • High helix carbide endmill
  • Carbide spot drill
  • Form tap
  • Collet holders
  • Shrink-fit holders
  • Sanding disk
  • Deburring tools
  • Air hose for blowing out holes
  • Cardboard dividers for packaging

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

  • Belt Tensioner Bracket