Exhaust Thermostat Flange

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Aerostar Manufacturing, based in Romulus, MI, demonstrates an unwavering commitment to producing high-quality exhaust thermostat flanges, marked by meticulous manufacturing processes, rigorous quality controls, and data-centric approaches. Their project reflects a dedication to precision from material reception through machining, inspection, and packaging, positioning them as an ideal partner for industries requiring excellence in manufacturing.


Aerostar Manufacturing, located in Romulus, MI, is steadfast in its dedication to both quality and efficiency. Recently, we embarked on a project focused on the manufacturing of the exhaust thermostat flange. This critical component plays a pivotal role in various applications, demanding a high level of precision and reliability. The manufacturing lifecycle has been meticulously designed to uphold unparalleled quality standards, ensuring excellence from raw material arrival to the final shipment of the finished product.

The commitment to quality is evident from the initial stage of the process – “Receive Material / Receive Inspection.” Materials undergo a thorough visual inspection to confirm the receipt of the correct product and to ensure there is no damage, contamination, or rust. The material then progresses through machining operations involving band saw, CNC, lathe, and CNC horizontal mill machines, each configured with specific tooling and quality control measures.

Quality assurance is seamlessly integrated into every phase of the manufacturing process. Various inspection methods, including attribute gages, variable gages, and Coordinate Measuring Machines (CMM), are employed to scrutinize dimensions, surface finish, and other critical attributes of the exhaust thermostat flange. The implementation of a “Zero Defects Allowed” policy emphasizes the stringent quality control measures in place, with any non-conformities triggering immediate supervisor notification and product isolation for further evaluation.

The Product Structure by Item Report system, updated as of June 2023, stands as a testament to Aerostar Manufacturing’s commitment to data-centric manufacturing. This system provides a comprehensive overview of the streamlined manufacturing process for each exhaust thermostat flange unit. It facilitates stringent control over production lines, optimizing resource allocation and ensuring on-time deliveries.

In terms of packaging, Aerostar Manufacturing adheres to industry standards. The “GP12 Inspection / Pack” stage involves a final visual inspection to guarantee correct identification and the absence of visual defects. Each exhaust thermostat flange is meticulously packed, with the process overseen by Quality and Engineering Managers to ensure the highest level of quality.

This exhaust thermostat flange manufacturing project serves as a testament to Aerostar Manufacturing’s unwavering commitment to delivering products of the highest quality and reliability. Their exhaustive evaluation protocols and multi-layered inspection processes position them as an ideal manufacturing partner for industries that demand nothing less than excellence.

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

  • Attribute Gages
  • Variable Gages
  • Coordinate Measuring Machine (CMM)
  • Visual Inspection Tools
  • Inspection Record Keeping 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 via first and last piece approval and in-process inspections (IPI).
  • 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

  • Saw
  • Milling Machines
  • Lathe
  • Various Machining Tools and Fixtures

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

  • Thermostat Cover
  • Bar Stock