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Aerostar Manufacturing, based in Romulus, MI, recently completed a meticulous project crafting “7K YOKE – KING PIN” components for Dana, showcasing their unwavering commitment to precision and reliability. From stringent material inspection to advanced machining and comprehensive quality controls, this project exemplifies Aerostar’s dedication to delivering top-tier products for industries that demand excellence.


Aerostar Manufacturing, based in Romulus, MI, demonstrates a resolute commitment to quality and efficiency. The recent project focused on crafting “7K YOKE – KING PIN” components for Dana exemplifies this dedication. Precision and reliability are paramount in the various applications for these components, necessitating a meticulous manufacturing lifecycle.

The journey begins with the “Receive Material / Receive Inspection” stage, where materials undergo visual scrutiny to confirm their correctness and check for damage, contamination, or rust. Following storage, the material progresses through machining processes involving Mill machines, guided by specific tooling configurations and stringent quality control measures.

Quality assurance is interwoven into every facet of the process. Diverse inspection methods, including attribute gages, variable gages, and Coordinate Measuring Machines (CMM), meticulously examine dimensions, surface finish, and critical attributes. The “Zero Defects Allowed” policy underscores the stringent nature of quality control, triggering immediate action upon any non-conformities.

The Product Structure by Item Report, updated as of May 2023, stands as a testament to our commitment to data-centric manufacturing. This system provides a comprehensive overview, enabling precise control over production lines and ensuring timely deliveries.

Packaging adheres to industry standards, culminating in the “WIP Packing Instructions” stage. A final visual inspection guarantees correct identification and the absence of defects. Each part undergoes careful packing overseen by Quality and Engineering Managers, ensuring the highest quality.

In essence, this project underscores Aerostar Manufacturing’s steadfast commitment to delivering products of unparalleled quality and reliability. The exhaustive evaluation protocols and multi-layered inspection processes position us as an ideal manufacturing partner for industries that demand nothing short of excellence.

Project Overview

Quality, Inspection, and Measurement Steps

  • Initial Material Inspection: Verify the integrity and specifications of incoming materials.
  • Visual Inspection: Check for visible defects, damage, or contamination.
  • Dimensional Inspection: Measure dimensions using appropriate tools to ensure they meet specifications.
  • Functional Testing: Test the functionality of components or assemblies.
  • Packaging Inspection: Ensure correct and secure packaging.
  • Final Audit: Conduct a comprehensive review of the product and its documentation.
  • Shipping Inspection: Verify the correct product, quantity, and identification before shipping.
  • Customer Feedback: Collect and analyze customer feedback for quality improvement.

Equipment and Tools Used for Quality and Inspection Tools

  • Variable Gages
  • Coordinate Measuring Machine (CMM)
  • Attribute Gages
  • Visual Inspection Tools

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 Preparation: Sort and prepare raw materials for manufacturing.
  • Setup: Configure machinery and tools for the specific manufacturing process.
  • Primary Machining: Perform initial cutting, milling, or shaping operations.
  • Secondary Operations: Perform additional processes like drilling, chamfering, or deburring.
  • Assembly: Assemble various components into a complete unit.
  • Quality Control: Implement quality checks and corrections.
  • Packaging: Pack the final product for shipping or storage.
  • Shipping: Prepare and send the product to the customer or next stage in the supply chain.

Equipment and Tools Used for Manufacturing Steps

  • Milling Machine: “CL”
  • Manual Clamps
  • Hydraulic Controller
  • Pallet Rotation Switch
  • Deburring Tools

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

  • Parent Item
  • Machined Components