Quality Control

1. Incoming Material Inspection

Objective: Ensure that all raw materials meet the required quality standards before entering the production process.

Raw Materials: Inspect all cast iron, steel, alloys, and non-ferrous materials to verify that they meet specifications (chemical composition, mechanical properties, etc.).
Supplier Certifications: Verify that suppliers provide material certificates that confirm compliance with industry standards (e.g., ASTM, DIN, ISO).
Visual Inspection: Check for defects such as cracks, rust, corrosion, and foreign inclusions.
Sampling and Testing: Randomly sample materials and conduct chemical analysis, tensile strength tests, and hardness tests using equipment like spectrometers and tensile testing machines.
Traceability: Assign batch numbers to materials for traceability throughout the manufacturing process.

Key Deliverables:

Objective: Ensure the castings are produced without defects and conform to the design specifications.

Mold Design & Pattern Inspection: Inspect mold patterns and core boxes for proper alignment and accurate dimensions.
Melting and Pouring: Monitor melting temperatures, pouring temperatures, and flow patterns to prevent defects such as porosity, shrinkage, and cold shuts.
Casting Quality Inspection:
Visual Inspection: Check for surface defects such as cracks, voids, and roughness.
Dimensional Inspection: Use coordinate measuring machines (CMM) and calipers to ensure the casting meets the dimensional specifications.
Non-Destructive Testing (NDT): Perform tests like Ultrasonic Testing (UT), Magnetic Particle Testing (MT), and Penetrant Testing (PT) to detect internal and surface defects.
Heat Treatment (Post-Casting): Apply stress-relief or annealing heat treatment as required to prevent cracks and warping.

Key Deliverables:

Objective: Ensure forged parts are produced with optimal strength and integrity.

Die Preparation and Inspection: Ensure dies and molds are properly prepared and inspected for defects, wear, and dimensional accuracy before forging.
Material Preheating: Monitor and control preheating temperatures of billets and bars to ensure proper flow during forging.
Forging Parameters: Monitor forging temperatures, pressing forces, and speed to ensure uniformity and prevent defects like cracking or mismatch.
Visual Inspection: Perform a visual check on the forged parts for surface imperfections, cracks, and surface integrity.
Dimensional Control: Measure forged parts with gauges and CMM equipment to verify conformance to design specifications.
Mechanical Testing: Perform tests such as tensile testing, impact testing, and hardness testing to confirm the forged part meets strength and durability requirements.

Key Deliverables:

Objective: Ensure that the finish machining process is accurate and the parts are dimensionally correct.

Machine Calibration: Regularly calibrate CNC machines, lathes, and other machining equipment to ensure precision.
Tool Selection: Ensure that the correct cutting tools, abrasives, and inserts are used for each material type.
Process Parameters: Monitor machining parameters such as feed rates, cutting speeds, and coolant usage to ensure optimal surface finish and avoid tool wear.
Dimensional Inspection: Use CMM, micrometers, and height gauges to verify that all machined surfaces meet the required tolerances.
Surface Finish: Measure surface roughness using tools such as profilometers or surface roughness testers to confirm the finish meets the specifications.

Key Deliverables:

Objective: Ensure the heat treatment process enhances the material properties and meets the required specifications.

Heat Treatment Parameters: Monitor and control critical parameters such as temperature, time, and cooling rate during hardening, tempering, annealing, nitriding, or carburizing processes.
Temperature Control: Use pyrometers and thermocouples to ensure accurate temperature control during heat treatment processes.
Quenching Media: Ensure proper quenching media (e.g., oil, water, polymer solutions) are used to avoid warping or cracking.
Post-Heat Treatment Inspection: Perform dimensional inspection and hardness testing to ensure that the parts have the desired properties after heat treatment.
Stress Relieving: After heat treatment, conduct stress relieving processes to prevent distortion or cracking.

Key Deliverables:

Objective: Ensure the final product meets all specifications and is free from defects.

Visual Inspection: Perform a final visual inspection to ensure there are no surface imperfections, cracks, or defects.
Dimensional Inspection: Recheck all critical dimensions using CMM and hand-held measuring tools to ensure conformance with the drawing.
Non-Destructive Testing: Perform NDT (e.g., UT, RT, MT, PT) as necessary for final verification of part integrity, especially for high-stress or safety-critical components.
Functional Testing: For components like gears, bearings, and shafts, conduct functional tests to verify performance (e.g., load-bearing tests, rotational tests).
Documentation: Ensure all inspection reports, test results, and material certificates are compiled and reviewed for compliance with client specifications and industry standards.

Key Deliverables:

Objective: Ensure products are properly packaged and shipped without damage.

Packaging Materials: Use appropriate protective packaging (e.g., foam, wooden crates, shrink wrap) to prevent damage during transit.
Labeling: Label all products with batch numbers, inspection approvals, and material certificates for traceability.
Shipping Inspection: Verify that the correct quantity of products is shipped and that no damage has occurred during handling or packing.

Key Deliverables:

Objective: Continuously monitor and improve the manufacturing process.

Root Cause Analysis: In case of defects or issues, conduct a root cause analysis to identify the underlying cause and implement corrective actions.
Employee Training: Regularly train employees on new quality control procedures, safety standards, and the latest manufacturing technologies.
Process Optimization: Continuously monitor and optimize key processes to improve efficiency and reduce defects.

Key Deliverables: