Industry(s): Marine
Application(s): Structural Components
Processes: Supply Chain Management, Inspection Services
Aerostar Manufacturing, located in Romulus, MI, upholds a high standard of precision and quality across all projects. Recently, we completed production of the “Engine RH V-Drive Mount,” a vital component requiring meticulous machining and stringent quality protocols throughout the production cycle.
Inspection Services
Aerostar Manufacturing, located in Romulus, MI, upholds a high standard of precision and quality across all projects. Recently, we completed production of the “Engine RH V-Drive Mount,” a vital component requiring meticulous machining and stringent quality protocols throughout the production cycle. From the initial receipt of materials to final packaging, each step is carefully designed to meet rigorous industry standards.
Our commitment to excellence begins at the “Receive Material / Receive Inspection” phase, where incoming materials undergo a thorough visual inspection to verify correct identification and assess for any signs of damage, contamination, or rust. Approved materials are then stored and prepared for the machining stages. In Operations 10A and 10B, advanced milling equipment is used to machine each part according to exact specifications, with tools and configurations tailored to ensure accuracy in dimensional tolerances and surface finishes.
Embedded quality control practices are a central aspect of our process. Inspections throughout the machining stages include multiple gaging methods—attribute gages for verifying diameter tolerances, variable gages for critical dimensions, and CMM inspections to check location accuracy and alignment. Each machined surface undergoes further examination to confirm finish quality, while visual inspections identify any potential surface defects. Additionally, quality assurance protocols enforce a “Zero Defects Allowed” standard, mandating immediate supervisor notification and isolation of any nonconforming products to maintain uncompromised quality.
Supporting our precision and efficiency, the Product Structure by Item Report, updated regularly, tracks every manufacturing and inspection step for the Engine RH V-Drive Mount. This tracking system enables data-driven improvements and ensures resource optimization, resulting in consistent quality and timely project completion.
At the final packaging stage, visual inspections validate that each component is correctly labeled and free from defects. Parts are then securely packed using approved materials, with quality oversight provided by our Quality and Engineering Managers to ensure optimal protection during shipment.
This project illustrates Aerostar Manufacturing’s dedication to precision and comprehensive quality assurance practices. Our methodical approach and commitment to zero defects make Aerostar an ideal partner for industries demanding high standards and reliable performance in their manufactured components.
Project Overview
Quality, Inspection, and Measurement Steps
- Visual Inspection: Check for correct product, identification, damage, and contamination.
- Attribute Gage Inspection: Verify dimensions using go/no-go gages for features like diameters and heights.
- Variable Gage Measurement: Use variable gages to measure precise tolerances on critical dimensions.
- Coordinate Measuring Machine (CMM) Inspection: Inspect location and alignment of features using CMM for accuracy.
- Surface Finish Verification: Evaluate surface finish quality using appropriate attribute gages.
- Runout and Flatness Testing: Measure runouts and flatness to ensure alignment and balance.
- Rust and Contamination Check: Assess parts for any rust or contamination that could affect performance.
- Defect Identification: Visually check for surface defects and anomalies that could impair function.
- Quality Tagging: Mark parts with quality approval or rejection tags based on inspection results.
- Dimensional Tolerance Verification: Confirm all specified dimensions within tolerance range.
Equipment and Tools Used for Quality and Inspection Tools
- Visual Inspection Tools (e.g., magnifying lamps)
- Go/No-Go Gages (e.g., pin gages for diameter checks)
- Variable Gages (e.g., calipers and micrometers for precise measurements)
- Coordinate Measuring Machines (CMMs) for multi-dimensional inspection
- Surface Finish Testers for assessing texture quality
- Runout Gages for circular and surface alignment
- Rust and Contamination Test Kits for surface quality checks
- Defect Tagging Tools for marking non-conforming products
- Dimensional Tolerance Verification Tools for in-process checks
- Measurement Documentation Systems to record inspection data
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 Inspection: Confirm correct materials upon receipt and inspect for any initial defects.
- Machining (e.g., Milling): Shape parts to precise dimensions and features using milling machines.
- Drilling and Spot Facing: Drill holes to specified dimensions and create flat seating surfaces as needed.
- Spotting and Counterboring: Prepare locations for bolt heads or additional machining with counterbored holes.
- End Milling: Refine shapes and edges with end mills for final contouring.
- Surface Finishing: Achieve consistent finish across all surfaces through media blasting or similar processes.
- Heat Treatment: Strengthen materials through controlled heating and cooling processes where specified.
- Rust Inhibitor Application: Apply rust-resistant coatings to extend product durability.
- Part Assembly (if applicable): Assemble components into final product format as per design specifications.
- Packaging and Storage: Pack finished parts following quality checks, then store for shipment.
Equipment and Tools Used for Manufacturing Steps
- Milling Machines for general shaping and contouring
- CNC Lathes for precise turning operations
- Drills and Spot Facing Tools for hole creation and surface preparation
- End Mills and Hog Mills for detailed cutting and final shaping
- Media Blasting Equipment for surface finishing and cleaning
- Heat Treatment Ovens for material strength enhancement
- Rust Inhibitor Sprayers for corrosion protection
- Assembly Jigs and Fixtures for part alignment during assembly
- Packaging Equipment to securely pack finished parts
- Storage Racks and Crates for organized holding before shipment
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
- Engine Mount
- Cast Components
- Machined Housings
- Finished Product Assemblies
- Fastening Inserts
- Threaded Holes and Studs
- Counterbored and Spot-Faced Features
- Surface-Finished Areas (e.g., media-blasted)
- Functional Seatings and Support Points
- Dimensional and Geometrically Toleranced Parts
Project Gallery
