At Aerostar Manufacturing, our fan hub assembly process stands as a testament to our unwavering commitment to the ISO-9001:2015 quality program. This intricate process starts with the precise installation of a pipe plug into the fan pulley, transitioning seamlessly to systematic greasing of the roller bearing. As we proceed, each component, from the snap ring securing the bearing to the careful positioning of the outer races, is methodically assembled, adhering to our stringent, standard-driven procedures. The culmination of our process sees the fan pulley fitted with a fan spacer gasket and a final quality check of shipping covers and assembly stamps. This rigorous, auditable approach not only guarantees the impeccable quality of our fan hubs but also offers our customers a transparent and traceable manufacturing journey, underscoring our dedication to excellence and accountability.
Assembly & Testing
The assembly process for the “fan hub”, as meticulously executed by Aerostar, is guided by the principles of the ISO-9001:2015 quality program. This globally recognized quality management standard ensures a strong customer focus, the involvement of top management, a process approach, and continual improvement.
The process commences with the installation of a pipe plug into the fan pulley, which is done following defined protocols and standard operating procedures to ensure accuracy and repeatability. The roller bearing is then greased using a systematic and precise process which involves placement over a threaded rod in a grease packer.
Following the greasing, the bearing is then carefully placed into the fan pulley and secured with a snap ring, per meticulous work instructions. Each step is executed with strict adherence to pre-defined procedures, guaranteeing product uniformity. The outer races of the roller bearing are methodically pressed into place using a designated driver, adhering to specified force and positioning requirements.
The assembly, which includes the fan pulley, spacers, a greased bearing, a plain washer, and a lock nut, is completed in a methodical, standard-driven manner ensuring consistent quality. Each step of the process, from greasing the cavity to torqueing the lock nut, is executed as per set guidelines, thereby minimizing variability and errors.
The assembly concludes with the fan pulley receiving a fan spacer gasket. Prior to packaging, the protective shipping cover and assembly stamps are subjected to visual inspections as per inspection procedures in line with ISO-9001:2015, ensuring their legibility and quality.
Every step of this assembly process performed by Aerostar is auditable, and complies with ISO-9001:2015 quality program, ensuring not only a high-quality fan hub but also a transparent, traceable manufacturing process for customers who value accountability and quality.
Quality, Inspection, and Measurement Tools
- Material Receipt Inspection: Conduct initial checks on received materials for compliance with specifications and for any visible damage.
- Store Material: Place the materials in controlled storage conditions, ensuring they are in good condition until used.
- In-Process Inspection: Conduct periodic checks during assembly to ensure each component fits and functions as intended.
- Functional Testing: Perform a test to ensure that the assembly functions as designed, following standard operating procedures.
- Final Audit: Inspect the completed assembly for any visual defects, correct identification, and ensure all quality requirements are met.
- End Play Test: Conduct specialized tests to check for mechanical compliance, such as tolerances or free play in assembled parts.
- Ship to Customer: Confirm that the completed assembly meets all quality criteria before shipping.
Equipment and Tools Used for Quality and Inspection Steps
- Visual Inspection Tools
- Measurement Gauges
- Functional Test Equipment
- Audit Checklists
- Dial Indicator for End-Play Test
Quality steps often intertwine with manufacturing steps to ensure that each component and the final assembly meet the specified standards. For instance, the Material Receipt Inspection aligns with the initial material receiving process in manufacturing. Similarly, in-process inspections are coordinated with various assembly steps to rectify any defects before the assembly is complete.
- Material Receiving: Receipt of all required materials and components.
- Material Storage: Safely store all received materials until they are ready for use.
- Component Assembly: Assemble all the components per the assembly instructions, ensuring correct fitting and alignment.
- Greasing and Sealing: Apply the necessary lubricants or seals to the respective parts of the assembly.
- Labeling and Barcoding: Attach appropriate labels or barcodes to the assembly for identification and tracking.
- Packaging: Pack the completed assembly per packaging guidelines.
- Shipping: Once the assembly has passed all quality checks, ship it to the customer.
Equipment and Tools Used for Manufacturing Steps
- Torque Wrench
- Driver Tools (Various types for different components)
- Bench Vise
- Grease Wand
- Packaging Materials (e.g., boxes, vapor coated layer pads, angle boards)
- Label Printer for Barcoding
Manufacturing steps often include checkpoints for quality inspection to ensure compliance with standards. For example, after Material Receiving, a Material Receipt Inspection is carried out to validate the quality of the components. Similarly, the Component Assembly phase has in-process inspections to ensure that each component is being fitted correctly.
Manufactured Components and Parts
- Lock Nut
- Oil Seal
- Fan Pulley
- Plain Washer
- Fan Hub Cover
- Roller Bearing Set