Industry(s): Automotive
Application(s): Structural Components
Processes: Supply Chain Management, Inspection Services
Aerostar Manufacturing, headquartered in Romulus, MI, remains committed to exceptional quality and efficiency. Recently, we undertook a project to produce an “Intake Manifold Cover,” a crucial component that requires precision and adherence to rigorous standards.
Inspection Services
Aerostar Manufacturing, headquartered in Romulus, MI, remains committed to exceptional quality and efficiency. Recently, we undertook a project to produce an “Intake Manifold Cover,” a crucial component that requires precision and adherence to rigorous standards. The production lifecycle for this part has been meticulously developed, ensuring consistent quality from the arrival of raw materials to the shipment of the finished product.
Our dedication to quality begins at the “Receive Material / Receive Inspection” stage, where materials undergo visual inspection for correct identification, product integrity, and to check for any damage, contamination, or rust. Once approved, materials are stored and subsequently prepared for machining processes involving advanced Mill equipment in Operations A & B. Each operation is configured with specific tooling and inspection protocols to maintain stringent standards.
Quality control is embedded throughout the process. Inspections utilize various gages—attribute gages for thread and diameter verification, variable gages for milled surfaces, and Coordinate Measuring Machines (CMM) for precise location checks. A visual inspection confirms surface finish and identifies any defects. Additionally, a leak test is conducted using pressurized air to ensure compliance with the 5cc/min maximum leak decay rate. This phase exemplifies our “Zero Defects Allowed” approach, ensuring immediate attention to any non-conformity by notifying supervisors and isolating affected products.
Aerostar’s commitment to quality control is supported by our Product Structure by Item Report, which was updated in June 2023. This report allows us to track every aspect of the manufacturing process for each Intake Manifold Cover unit, providing a data-driven approach to optimize resources and ensure timely delivery.
At the packaging stage, final visual inspections confirm that all parts are correctly identified and free of defects. Afterward, each component is securely packed with the appropriate materials and labeling, overseen by our Quality and Engineering Managers to maintain the highest quality standards.
This project underscores Aerostar Manufacturing’s relentless commitment to delivering reliable, high-quality products. Our comprehensive quality assurance practices and multi-layered inspection processes make us an optimal manufacturing partner for industries requiring uncompromised precision and excellence.
Project Overview
Quality, Inspection, and Measurement Steps
- Verify product identification, quantity, and ensure there are no visible defects.
- Conduct visual inspection for surface finish and visual defects.
- Perform dimensional inspections with attribute and variable gages for critical measurements.
- Conduct thread and bore inspections using plug and thread gages.
- Inspect machined surfaces for flatness and correct specifications.
- Conduct cleanliness tests using Millipore or similar systems.
- Verify packing materials, labeling, and part orientation for accuracy.
- Confirm major, critical, and significant characteristics as specified by quality control standards.
- Conduct leak tests using pressurized air or other standard mediums.
- Record and document all findings, marking any nonconformities for immediate attention.
Equipment and Tools Used for Quality and Inspection Tools
- Visual inspection tools (magnifiers, lighting systems)
- Variable gages (dial indicators, micrometers)
- Attribute gages (plug gages, thread gages)
- Coordinate Measuring Machines (CMMs)
- Leak testing equipment (air pressure setup)
- Millipore system for cleanliness checks
- Barcode scanners for identification verification
- Calipers and flatness indicators for surface inspection
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
- Receive and verify raw materials for correct type and quality.
- Prepare raw materials by washing or cleaning as needed.
- Conduct machining operations, including milling, drilling, and tapping.
- Deburr or smoothen machined edges to eliminate sharp or rough surfaces.
- Conduct thread forming and internal hole finishing for threaded components.
- Perform final cleaning to remove machining residues and prepare parts for subsequent processes.
- Assemble components into sub-assemblies or final assemblies, ensuring proper alignment and fit.
- Package parts following specified orientations and protective requirements.
- Label, scan, and verify all completed parts for accurate shipping and customer specifications.
- Ship final products or assemblies to customers or other manufacturing departments.
Equipment and Tools Used for Manufacturing Steps
- CNC milling machines
- Hydraulic clamps and fixtures
- Spot and counter-sink drills
- Multi-tools for roughing, semi-finishing, and finishing
- Form taps for threading operations
- Carbide mills for precision cutting
- Deburring tools (deburring blades, countersink bits)
- Packaging equipment (corrugated pads, cell dividers)
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
- Intake manifold cover
- Castings
- Machined holes (threaded and non-threaded)
- Drilled through-holes
- Threaded bores and ports
- Surface finishes
- Packaged and labeled assemblies
Project Gallery
