Industry: Aerospace, Automotive, Heavy Truck, Marine, Industrial, Power Generation
Application(s): Engine Components
Processes: Assembly and Testing, Inspection, Stamping, Leak Testing
Aerostar Manufacturing implemented meticulous receive inspections, precise assembly, and rigorous quality checks to successfully deliver high-quality Oil Cooling Housings to a valued client. By adhering to ISO-certified processes, conducting advanced leak testing, and carrying out comprehensive visual inspections, Aerostar solidified its reputation as a reliable partner for complex assembly projects, reflecting its commitment to maintaining the highest quality standards across diverse industries.
Aerostar Manufacturing was entrusted with the critical task of assembling Oil Cooling Housings for a prominent client. The Oil Cooling Housing Assembly Process involved meticulous steps to ensure top-notch quality and precision in the final product. This case study delves into the comprehensive process employed by Aerostar to meet client requirements and uphold their commitment to excellence.
The process began with a thorough receive inspection, during which Aerostar’s expert technicians visually inspected each component for correctness, damages, and any potential contamination or rust. Once deemed suitable, the materials were stored securely to maintain their integrity until the assembly process.
At the assembly station, Aerostar’s skilled team expertly assembled various components, including 2870232, 3678921, 4965483, 4965484, 4965487, and 4966084. They employed an Air Sensor to verify the presence of 4386026 and 3690535, and the S.A.M. Unit to verify the installation of 4386030. Rigorous visual inspections were conducted to ensure proper installation and orientation of S16255, and a PLC confirmed the installation and torque verification of 3690536 and 3090400. After assembly, a Leak Decay Test was performed to assess the integrity of the assembled Oil Cooling Housing.
Following the assembly and leak test, the Oil Cooling Housings underwent a comprehensive stamping and labeling process. The team visually inspected for the presence and correctness of human-readable text and barcode identification, ensuring label print quality and correct label location and orientation on the part. Barcode scanning systems were used to verify present and correct identification. A final visual inspection was conducted to ensure proper packing materials, dunnage, and to identify any obvious machining or casting defects.
Aerostar Manufacturing maintains stringent quality control processes. A final audit was conducted to visually inspect for correct identification and to identify any visual defects before the assembled Oil Cooling Housings were ready for shipment. The team conducted a final visual inspection, verifying that the product was correct, free from damages, and met all customer specifications before shipping to the valued client.
With ISO 9001:2015 certification, Aerostar ensures their processes consistently meet customer requirements, delivering Oil Cooling Housings that conform to international quality standards. These certifications testify to Aerostar’s dedication to providing superior products and maintaining a reputation for excellence in the industry.
Through meticulous receive inspections, precise assembly, and rigorous quality checks, Aerostar Manufacturing successfully delivered top-notch Oil Cooling Housings to their esteemed customer. The adherence to ISO-certified processes, advanced leak testing, and comprehensive visual inspections have solidified Aerostar’s reputation as a reliable partner for complex assembly projects. This case study highlights Aerostar’s commitment to maintaining the highest quality standards and delivering flawlessly assembled products to customers across diverse industries.
Project Overview
Quality, Inspection, and Measurement Tools
- Receipt inspection: Visual inspection for the correct product, damage, contamination, and/or rust.
- Inspection for proper assembly: Verify correct installation and orientation.
- Leakage testing: Ensure product does not have any unwanted gaps or holes.
- Verification of readable text & barcode: Confirming print quality, location, and orientation.
- Final audit: Inspect for correct identification and visual defects before shipping.
Equipment and Tools Used for Quality and Inspection Steps
- Air Sensor.
- S.A.M. Unit.
- PLC system.
- Barcode Scanning System.
- Visual inspection tools.
These quality steps can occur concurrently with or after certain manufacturing processes to ensure the product meets desired specifications. It’s essential for quality checks to be intertwined with the manufacturing process to streamline production and reduce rework or waste^
Manufacturing Steps
- Storing the raw materials.
- Assembling the components.
- Leak testing the assembled product.
- Marking: Stamping, barcoding, and labeling.
- Packing: Ensuring correct packing materials and orientations.
- Final storage before shipping.
- Shipping to the client.
Equipment and Tools Used for Manufacturing Steps
- Machine with clamps for holding parts.
- Torque gun.
- HMI display system.
- Tohnichi wrench.
- Leak test machine.
- Stamping machine.
- Shipping container.
Manufacturing steps, particularly the assembly and packing processes, often necessitate inspection at various stages to verify that quality standards are met. These checks help in early detection of any discrepancies and save both time and resources
Manufactured Components and Parts
- Housing assembly.
- Oil cooler housing component.
- Threaded plug component.
- Twelve-point cap screw component.
- Mounting spacer.
- Cooler core component.
- O-ring seal component.
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