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: 100,000
Aerostar Manufacturing, located in Romulus, MI, maintains a steadfast commitment to excellence in manufacturing and customer satisfaction. Recently, we completed a significant project focused on the production of light-duty casters. These components are essential across various applications, requiring precise engineering and reliable performance.
Our manufacturing process begins with rigorous material inspection upon receipt, ensuring quality and integrity. Following material storage, we employ specialized lathe and mill machines for machining, each equipped with specific tool configurations and stringent quality checks.
Quality assurance is integral throughout our process, incorporating diverse inspection methods such as attribute and variable gauges, as well as Coordinate Measuring Machines (CMM). Our “Zero Defects Allowed” policy underscores our dedication to delivering flawless products. Any deviations prompt immediate action, including product isolation for thorough evaluation.
To optimize efficiency, our state-of-the-art Product Structure by Item Report system, updated as of June 2023, provides detailed insights into each unit’s manufacturing journey. This data-driven approach ensures precise control over production schedules and resource allocation, facilitating timely deliveries.
Adhering to industry standards, our final packaging stage involves meticulous visual inspections and careful packing overseen by our dedicated Quality and Engineering Managers. This ensures that each caster meets our stringent quality benchmarks before shipment. This project exemplifies Aerostar Manufacturing’s unwavering commitment to excellence in manufacturing, ensuring that our products consistently meet the highest standards of quality and reliability.
Project Overview
Quality, Inspection, and Measurement Steps
- Receive Inspection: Ensure received materials meet quality standards.
- Storage Condition Check: Verify parts are stored in proper conditions to prevent defects.
- Dimensional Inspection: Measure diameters, heights, and lengths using variable gauges or CMM (Coordinate Measuring Machine).
- Surface Finish Inspection: Inspect surface finish via attribute gauges.
- Runout Inspection: Check for deviations using CMM.
- Visual Inspection: Inspect parts for obvious defects.
- Identification Inspection: Ensure parts are correctly identified and labeled.
- Final Inspection: Conduct a comprehensive review before shipping to ensure all quality standards are met.
- In-Process Inspection: Monitor parts during production to identify any defects early.
- SPC (Statistical Process Control) Data Collection: To evaluate, monitor and control the process (Continuous Improvement).
- Nonconformance Tagging: Label and segregate defective parts for further review.
Equipment and Tools Used for Quality and Inspection Tools
- Variable Gauges: For measuring dimensions.
- Coordinate Measuring Machine (CMM): For precise dimensional measurements and runout inspections.
- Attribute Gauges: For surface finish inspection.
- Calipers: For measuring diameters and lengths.
- Digital Micrometers: For high precision measurements.
- Go/No-Go Gauges: For quick pass/fail inspection.
- Chamfer Gauges: For measuring chamfer dimensions.
- Visual Inspection Tools: Magnifying glasses, lights.
- Depth Gauges: For measuring depths of drilled holes.
- Profilometers: For measuring surface roughness.
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 Reception: Receive raw materials and verify against specifications.
- Storage: Store materials in conditions that prevent deterioration.
- Initial Machining: Perform primary machining operations such as milling or turning.
- Secondary Machining: Conduct additional machining operations to refine part dimensions.
- Intermediate Storage: Store semi-finished parts in proper conditions.
- Final Machining: Complete all machining processes to achieve final part specifications.
- Finishing Operations: Perform finishing processes such as polishing or coating.
- Assembly: Assemble parts as per design requirements.
- Packing: Pack finished parts following specified packaging instructions.
- Shipping: Dispatch the packed parts to the customer.
Equipment and Tools Used for Manufacturing Steps
- Milling Machines: For primary machining operations.
- Lathes: For turning operations.
- Drilling Machines: For creating holes.
- Grinding Machines: For finishing operations.
- CNC Machines: For precision machining.
- Hydraulic Clamps: For securing parts during machining.
- End Mills: For milling operations.
- Spot Drills: For creating pilot holes.
- Tool Holders: For securing tools in machining centers.
- Shrink Fit Holders: For high-precision tool holding.
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
- Shafts
- Actuators
- Bearings
- Gearboxes
- Housings
- Covers
- Couplings
- Seals
- Spacers
- Bolts and Fasteners
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