Quality management system processes
Quality is produced at every station, not at final inspection. From incoming material to shipment we work with five quality gates, recorded measurements and a defined problem-solving discipline. System documents and audit information are shared on request.
Five gates, five defined outputs
Who measures what, and how often, at each gate is written in the control plan.
- Gate 1
Incoming material
Matching of material certificates, spectral analysis, hardness and dimensional sampling. A non-conforming batch is quarantined.
- Gate 2
First-piece approval
The first piece is measured at every tool and fixture change; series production does not start without approval.
- Gate 3
In-process control
Special characteristics are monitored with statistical process control; the line stops when a control limit is exceeded.
- Gate 4
Final inspection
Batch-based measurement in the measurement room, visual inspection and function tests; the measurement report is linked to the batch.
- Gate 5
Shipping release
Label, quantity, packaging and document checks; the shipping record is entered into the traceability system.
Measurements are recorded and trends watched
Control charts for special characteristics are kept at the line; a reaction rule is defined for out-of-limit readings.
- Measurement frequency defined in the control plan
- Measurement system analysis for gauge and operator suitability
- Capability tracking and periodic review
- Line-stop and quarantine rule on deviation
A temperature-controlled measurement room and instruments
Instrument calibration follows a schedule; each instrument's calibration record is linked to the measurement report.
Coordinate measurement
Position, flatness and perpendicularity measurement on housing and block parts; repeatable reports through a part program.
Surface and contour
Roughness, contour and roundness measurement for bearing and sealing surfaces.
Material and hardness
Spectral analysis, hardness and microstructure checks; case depth is verified on a section.
Function and leak tightness
Leak tightness by air pressure decay, press-fit force and torque records, pedal force test.
The discipline the automotive supply chain expects
New part launches follow an advanced product quality planning approach: process flow chart, failure mode and effects analysis, control plan and measurement system analysis are prepared together. The sample approval file is compiled to the level the customer requires.
- Process flow chart and control plan
- Failure mode and effects analysis (design and process)
- Sample approval file and measurement reports
- 8D problem solving and root-cause analysis
- Customer complaint and corrective action tracking
From part to batch, from batch to ingot
Every part is marked with a laser DMC code. The code is linked to the casting batch, heat-treatment charge, machine tool, measurement report and shipping document. If a field failure is reported, the affected batch can be narrowed down within minutes.
- 1Raw material batch and material certificate
- 2Casting cell, tool number and shift
- 3Heat-treatment charge record
- 4Machine tool and tool-life record
- 5Measurement report and shipping document