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: 9,000
Aerostar Global Manufacturing, situated in Romulus, MI, USA, epitomizes a steadfast dedication to excellence in both quality and efficiency. In our recent endeavor focusing on the production of the “Engine Mount Trunnion,” we upheld stringent standards to ensure precision and reliability for high-performance marine applications. The manufacturing journey of this component has been intricately designed to uphold unparalleled quality standards, from the initial arrival of raw materials to the final dispatch of the finished product.
Our unwavering commitment to quality begins with the “Receive Material / Receive Inspection” phase, where materials undergo a meticulous visual inspection to verify product correctness and to mitigate any potential damage or contamination. Following material storage, machining operations are executed utilizing advanced CNC machining techniques, with each operation meticulously monitored to ensure adherence to quality control measures.
Quality assurance permeates every facet of our process, with various inspection methods such as Coordinate Measuring Machines (CMM) employed to scrutinize critical dimensions, surface finish, and other essential attributes of the part. Our “Zero Defects Allowed” policy underscores the rigor of our quality control measures, with any deviations triggering immediate supervisor notification and subsequent isolation of non-conforming products for further evaluation.
Adhering to industry standards, our packaging process includes detailed protocols to prevent damage and contamination during transportation. Each part is meticulously packed and prepared for shipping under the oversight of our Quality and Engineering Managers, ensuring the highest level of quality is maintained throughout.
This project underscores Aerostar Global Manufacturing’s unwavering commitment to delivering products of the utmost quality and reliability. Our exhaustive evaluation protocols and multi-layered inspection processes position us as an ideal manufacturing partner for industries that demand nothing less than excellence.
Project Overview
Quality, Inspection, and Measurement Steps
- Material Inspection: All raw materials undergo rigorous quality checks for compositional and structural integrity before entering the production line.
- Dimensional Inspection: Precision measurement tools are used to ensure all dimensions meet the exact specifications detailed in the engineering drawings.
- Non-Destructive Testing (NDT): Techniques such as ultrasonic testing and X-ray inspection are employed to detect internal flaws without damaging the part.
- Surface Finish Inspection: The surface quality is checked to ensure it meets the required roughness and finish standards, critical for performance and longevity.
- Final Inspection: A thorough inspection is conducted on the finished product to confirm it meets all mechanical and dimensional criteria.
Equipment and Tools Used for Quality and Inspection Tools
- Variable gages
- Coordinate Measuring Machine (CMM)
- Attribute gages
- Visual inspection tools
- Packing materials
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
- Design and Engineering: The process begins with CAD modeling and FEA analysis to design the Trunnion, ensuring it meets all structural requirements.
- Material Selection: Based on the design, the appropriate material is selected for its mechanical properties, such as strength and resistance to wear and fatigue.
- Forging: The raw material is forged into the rough shape of the Trunnion to enhance its mechanical properties and ensure uniformity.
- CNC Machining: Precision CNC machines are used to achieve the final dimensions and tolerances, ensuring each part is identical and meets the stringent requirements.
- Heat Treatment: The parts undergo heat treatment processes to enhance their mechanical properties, such as hardness and tensile strength.
- Surface Treatment: Treatments such as anodizing or coating are applied to improve corrosion resistance and surface finish.
Equipment and Tools Used for Manufacturing Steps
- Milling machine
- Manual clamps
- Hydraulic controller and hoses
- Hydraulic clamps
- Pallets and plywood boards
- Deburring tools (such as pencil grinder and manual deburring tool)
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
- Engine Blocks: Critical for housing the cylinders and other engine components, ensuring the overall structural integrity of the engine.
- Transmission Mounts: Designed to support the transmission system, reducing vibrations and maintaining alignment with the engine.
- Suspension Components: Precision engineered parts that ensure the stability and performance of a vehicle’s suspension system.
- Pump Housings: Essential for enclosing and protecting the pump mechanisms, ensuring efficient fluid transfer.
- Axle Components: Including shafts and joints, which are crucial for the proper functioning and durability of the vehicle’s drivetrain.