Aerostar Manufacturing, based in Romulus, MI, specializes in producing high-quality fan support components, adhering to rigorous quality control measures throughout the component’s lifecycle. Utilizing an intricate process and inspection flowchart, the company employs a range of inspection methods, from initial visual checks to complex dimensional evaluations using specialized equipment like CMMs, attribute gages, and calipers. Their thorough approach ensures each component is defect-free and precisely engineered, bolstered by internal audits and documentation, setting a strong foundation for future projects and partnerships.

Aerostar Manufacturing, based in Romulus, MI, is a leading provider of specialized fan support components. With a focus on quality and reliability, Aerostar’s team followed an intricate process and inspection flowchart for the entire lifecycle of the component. The detailed approach encompassed everything from the initial reception of raw materials to the final audit prior to shipment. Multiple checkpoints were incorporated into the process, including visual inspections for defects, surface finish, and correct identification, as well as dimensional checks via attribute gages, variable gages, and CMM (Coordinate Measuring Machine).

The manufacturing process began with the reception the part, followed by an initial visual inspection for the correct product, possible damage, and signs of contamination or rust. Each casting underwent rigorous pre-machining inspections. During the machining stage, milling machines loaded with multiple CNC programs were employed to craft the fan support parts with precision. Each component was subject to thorough evaluations at multiple stages. These included dimensional checks for hole diameters, counterbore dimensions, and surface heights using specialized tools like go/no-go gage pins, calipers, and height gages. Detailed records were maintained on data collection sheets and underwent audits by internal corporate quality managers, production managers, and engineering VPs.

After machining, each fan support component was exposed to a final audit. This incorporated a series of visual inspections for the correct product and identification, along with checks for damage, contamination, or rust. Subsequently, components were barcoded and packaged, guaranteeing accurate identification and freedom from visual defects. Throughout the production cycle, Aerostar’s internal documents such as the Job Jacket Review Form, Tool Sheet, and In-Process Inspection (IPI) documents were indispensable for seamless execution and quality assurance. As a result, Aerostar Manufacturing successfully produced high-quality, precision-engineered fan support components, laying a solid foundation for future projects and partnerships.

Project Overview

Quality, Inspection, and Measurement Tools

  • Receipt and Initial Inspection: Visually inspect for correct product, damage, contamination, or rust.
  • Pre-Machining Inspection: Perform rigorous checks on raw materials or semi-finished components.
  • In-Process Inspection: Check dimensions, surface finish, and other criteria at various stages during manufacturing.
  • Final Audit: Conduct thorough visual inspections for correct identification and defects.
  • Packaging Inspection: Ensure present and correct identification and visual integrity.
  • Pre-Shipment Inspection: Confirm correct product, identification, damage, or contamination before shipping.

Equipment and Tools Used for Quality and Inspection Steps

  • Attribute Gages
  • Variable Gages
  • Variable Location Gages
  • Coordinate Measuring Machines (CMM)
  • Calipers
  • Height Gages
  • Go/No-Go Gage Pins
  • Visual Inspection Tools

Quality and inspection steps often intertwine with the manufacturing process. For instance, inspections often follow significant manufacturing steps like machining or finishing to ensure the integrity and accuracy of the produced components. They can lead to modifications in the manufacturing steps if defects are detected.

Manufacturing Steps

  • Material Storage: Store the raw materials until they are ready for use.
  • Pre-Machining: Prepare the raw materials or semi-finished components for main production.
  • Machining: Utilize appropriate machines to shape and form the parts.
  • In-Process Adjustments: Make any necessary adjustments during the manufacturing process.
  • Final Machining: Complete the last machining steps, if any.
  • Finished Material Storage: Store the finished materials until they are ready for the next stage.
  • Packaging: Barcode and package the components for shipping.
  • Shipping: Ship the final product to the customer.

Equipment and Tools Used for Manufacturing Steps

  • Milling Machines
  • CNC Programs
  • Drills
  • Spot Drills
  • Endmills
  • Facemills
  • Taps
  • Collet Holders
  • Shell Mill Holders

Manufacturing steps often precede or follow a quality check or inspection. This ensures that the component moves to the next phase of manufacturing only when it meets all the required quality standards. Failure in inspections often loops the component back to an appropriate manufacturing step for rework.

Manufactured Components and Parts

  • Support Structures (e.g., Fan Support)
  • Castings (e.g., Fan Support Casting)
  • Finished Components (e.g., Packed or Unpacked)
  • Semi-Finished Components
  • Barcoded Items