Industry(s): Aerospace, Automotive, Marine
Application(s): Transmission Systems, Engine Mounts, Structural Components
Processes: Supply Chain Management, Inspection Services
Aerostar Manufacturing, situated in Romulus, MI, prides itself on an unwavering commitment to quality and efficiency. In 2018, we undertook a project to manufacture specialized trunnion parts for transmission mounts. These components are critical in high-performance marine applications.
Inspection Services
Annual Usage: 2,000
Aerostar Manufacturing, situated in Romulus, MI, prides itself on an unwavering commitment to quality and efficiency. In 2018, we undertook a project to manufacture specialized trunnion parts for transmission mounts. These components are critical in high-performance marine applications. The manufacturing lifecycle for this component was meticulously designed to ensure top-notch quality from material reception to the final product shipment.
Our quality assurance starts at the “Receiving Inspection” step, where materials received from Reed Manufacturing are inspected against REC_E100145 requirements. Here, a visual inspection ensures the correct product is received free from damage, contamination, or rust. Following material storage, the product undergoes another set of stringent checks during the packaging phase. We verify proper identification and inspect for correct packing materials, obvious machining, and casting defects. A final audit is conducted to ensure that each component meets all the quality specifications laid down by us and the customer, from identification to the absence of any packaging errors. Our exhaustive evaluation protocols, scrutinizing all major, critical, significant, and pass-through characteristics, have been crucial in minimizing error rates and delays.
Our advanced Product Structure by Item Report system, as of June 2023, indicates the streamlined process behind each trunnion unit, signifying effective supply chain management. This data-driven approach allows us to maintain tight controls on our production process, optimizing resource utilization while ensuring timely deliveries.
For packaging, we use industry-standard materials, including a 7 3/4 X 7 X 4 3/4 general-use cardboard box. The parts are packed as shown, and a dividing cardboard is placed between vertical and horizontal pieces. After packing the final layer, another piece of cardboard is placed on the top, and the box is sealed with tape. These specific packaging steps are conducted by the Assembly/Shipping/Packaging Department and are overseen by our Quality and Engineering Managers to ensure top quality.
This case study exemplifies Aerostar Manufacturing’s dedication to delivering unparalleled quality and reliability. Our multi-layered inspection and reporting protocols make us an ideal partner for industries demanding high standards.
Project Overview
Quality, Inspection, and Measurement Tools
- Initial Material Receipt Inspection: Check for correct product, damage, contamination, or rust.
- Visual Inspection: Examine all components for machining and casting defects.
- Intermediate Inspection: Verify correct identification of components during the manufacturing process.
- Final Audit: Confirm the presence and correctness of identification on parts and shipping containers, and inspect for product defects, packing, and packaging errors.
- Pre-shipment Inspection: Review for correct product, quantity, identification, and any signs of damage or contamination.
Equipment and Tools Used for Quality and Inspection Steps
- Visual Inspection Cameras
- Measuring Tapes
- Micrometers
- Material Testing Kits
- Identification Scanners
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 Sourcing: Procure necessary raw materials.
- Material Storage: Store materials in conditions to prevent degradation.
- Assembly: Assemble the components per the specifications.
- Leak Testing: Conduct tests to check for leakages.
- Packaging: Secure the products with correct packing materials and identification.
- Shipping: Send the product to the customer.
Equipment and Tools Used for Manufacturing Steps
- CNC Machines
- Welding Equipment
- Assembly Jigs
- Leak Testing Machines
- Packaging Machines
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
- Fasteners
- Mounting brackets
- Transmission mounts
- Dividers
- Cardboard packaging boxes
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