Industry(s): Automotive
Application(s): Structural Components
Processes: Supply Chain Management, Inspection Services
Aerostar Manufacturing in Romulus, MI, USA, prioritizes quality and reliability in its production processes. Our meticulous inspection procedures, from material receipt to final packaging, ensure adherence to stringent quality standards.
Inspection Services
Annual Usage: 1,200
Aerostar Manufacturing, headquartered in Romulus, MI, is dedicated to excellence in both quality and efficiency. Recently, we undertook a significant project centered on the production of Front Engine Supports. These components play a critical role in various applications, requiring precise manufacturing processes and utmost reliability. The lifecycle of manufacturing these parts has been meticulously designed to ensure unparalleled quality from the moment raw materials arrive to the final shipment of the completed units.
Our commitment to quality begins with the “Receive Material / Receive Inspection” stage, where incoming materials undergo visual inspection to verify their correctness and ensure they are free from damage, contamination, or rust. Post-inspection, materials are stored and processed through dedicated Lathe and Mill machining operations, each employing specific tooling configurations and rigorous quality control protocols.
Quality assurance is deeply embedded in every phase of our manufacturing process. We utilize a range of inspection methods, including attribute and variable gauges, as well as Coordinate Measuring Machines (CMM), to meticulously assess dimensions, surface finishes, and other critical parameters of the Front Engine Supports. Our “Zero Defects Allowed” policy underscores the strictness of our quality controls, triggering immediate supervisor notification and isolation of any non-conforming products for further evaluation.
Powered by our advanced Product Structure by Item Report system, current as of June 2023, we maintain comprehensive oversight of the manufacturing process for each Front Engine Support unit. This data-driven approach allows us to optimize production efficiency and resource allocation while ensuring on-time deliveries.
Adhering to industry standards, our packaging process includes the “GP12 Inspection / Pack” phase, where each unit undergoes a final visual inspection to confirm accurate identification and absence of visible defects. Each Front Engine Support is then meticulously packaged under the supervision of our Quality and Engineering Managers to uphold the highest standards.
The Front Engine Support project exemplifies Aerostar Manufacturing’s steadfast commitment to delivering products renowned for their quality and reliability. Our rigorous evaluation protocols and multi-layered inspection procedures position us as the preferred manufacturing partner for industries demanding nothing short of excellence.
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Project Overview
Quality, Inspection, and Measurement Steps
- Receive Inspection: Inspect for correct product, damage, and contamination; Store material appropriately if not applicable.
- In-Process Inspection: Use attribute gauges for dimensions, ports, and threads; Use variable gauges for milled faces and locations; Conduct visual inspection for surface finish and visual defects.
- Final Inspection: Visual inspection for correct product, identification, and defects.
- Packaging and Shipping Inspection: Inspect for debris and liquid; Verify barcode and label accuracy; Check packaging materials and visual defects.
Equipment and Tools Used for Quality and Inspection Tools
- Coordinate Measuring Machines (CMM)
- Attribute gauges for dimensions, ports, and threads.
- Variable gauges for milled faces and locations.
- Visual inspection tools for surface finish and defects.
- Barcode scanning system.
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 Handling and Storage: Receive materials and store appropriately.
- Machining Operations: Milling processes using specific tools (e.g., facemill), Drilling and tapping operations with carbide drills and taps, Cutting and chamfering holes as required.
- Finishing Operations: Finalize surfaces with facemill operations and Complete drilling, chamfering, and tapping operations.
- Assembly and Packaging: Prepare parts for assembly and packaging.
Equipment and Tools Used for Manufacturing Steps
- Milling machine
- Manual clamps
- Hydraulic controller and hoses
- Hydraulic clamps
- Pallets and plywood boards
- Deburring tools (such as pencil grinder and manual deburring tool)
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
- Front Engine Support
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