Aerostar Manufacturing is a FULL-SERVICE machining company with manufacturing facilities in the United States, offices and partner facilities in India.

 A truck OEM needed a casting to be machined and then assembled for an engine fuel block connection with a focus on efficiency and cost reduction. Rather than source 2 separate vendors for these processes, Aerostar provided a comprehensive solution that streamlined the process from casting to assembled product.

Visual Inspection: Upon arrival at Aerostar’s warehouse, the castings undergo a rigorous visual inspection to ensure they meet the required specifications and are free of rust or debris. The castings are then precisely machined using a CNC machine to achieve the desired dimensions and tolerances.

After machining, any remaining burrs or rough edges are removed through a meticulous deburring process. Machined castings are assembled with a variety of the following components: Connectors, couplings, adapters, O-ring seals, and clips. Each assembled unit undergoes a thorough leak test to ensure fuel system integrity. All assembled units are then washed to remove any residual contaminants. The finished fuel block connection assemblies are carefully packed and shipped to the customer.

Results:
  • Increased Efficiency: Aerostar’s streamlined process significantly reduced the lead time for the fuel block connection assemblies, improving the OEM’s production efficiency.
  • Cost Reduction: By optimizing the machining process and utilizing lean manufacturing principles, Aerostar was able to deliver the assemblies at a competitive price, reducing the OEM’s overall production costs.
  • Quality Assurance: Aerostar’s ISO 9001 and IATF 16949 certifications guarantee the highest quality standards for the fuel block connection assemblies, giving the OEM complete confidence in their performance and reliability.

This case study demonstrates how Aerostar Manufacturing’s expertise in precision machining, production machining, assembly, and quality control can help manufacturers optimize their production processes, reduce costs, and achieve superior results. By partnering with Aerostar, the customer was able to streamline its fuel block connection assembly production, improve efficiency, and gain a competitive edge in the market.

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

  • Variable Gages
  • Coordinate Measuring Machine (CMM)
  • Attribute Gages
  • Visual Inspection 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.
  • Washing: Wash Parts to prep for assembly
  • Packaging: Pack the final product for shipping or storage.

Equipment and Tools Used for Manufacturing Steps

  • Milling machines (Mill A & B)
  • Diamond Face Mill
  • Carbide drills
  • High helix carbide endmill
  • Carbide spot drill
  • Form tap
  • Collet holders
  • Shrink-fit holders
  • Sanding disk
  • Deburring tools
  • Air hose for blowing out holes
  • Cardboard dividers for packaging

Aerostar Manufacturing is ISO 9001 certified, IATF:16949 certified, and is an NMSDC MBE, which means they are a certified minority-owned business enterprise. This can be an attractive factor for companies looking to support diversity in their supply chain.