Meeting and Exceeding Fabrication and Machining Expectations through Quality
Quality is the key to success in machining and fabrication projects. As a manufacturer, your objective is to demonstrate quality that is exact — meaning the product quality can be defined, verified, and repeated again and again. More simply, a robust quality control program enables parts to be manufactured without defect, meeting and exceeding design specifications and able to function properly. Quality control also ensures customer satisfaction. Machine shops that deliver a high level of quality are able to enjoy many benefits including production efficiency, customer loyalty, less waste generation, and a lower level of production risk. In addition to higher product quality, sound quality control that drives consistent work practices often leads to a safer workplace for personnel.
One of the advantages of partnering with a proven machine shop, like ABS, is access to more advanced quality control processes and state-of-the-art technologies. Machining partners that are committed to quality invest in cutting-edge automation and other advanced equipment that accelerates the pace of production and elevates product quality. These manufacturers focus on continuous improvement initiatives and lean manufacturing – practices that result in tighter quality control, saving OEMs time and money. At ABS, we pride ourselves on the utilization of cutting-edge technologies for our customers. Our team fosters a continuous improvement mind-set, and we never rest when it comes to quality.
Below are some best practices for meeting and exceeding fabrication and machining expectations through quality control. ABS employs these practices throughout our quality management program, enabling our team to deliver outstanding product quality for our customers.
- Ensure Alignment: clear communication between a machining partner and the customer is critical to the success of a fabrication project. Clear communication upfront and implementing quality control measures early prevent mistakes and costly downtimes in the future. Both parties must be aligned about the expectations for the final product so the machine shop can establish the quality control measures and standards necessary to achieve the specifications and requirements for a given project. Specifically, the machine shop and customer must be aligned on the machining and fabrication processes, procedures and equipment to be used, the part specifications and tolerances, and the quality measures including traceability, inspections, and record keeping.
- Certifications and Compliance: OEMs need a trusted machining partner with a reliable and dependable process that yields consistent results – and unfortunately, not all machine shops demonstrate solid quality control systems. When evaluating potential machining partners, you must consider the certifications they have obtained. Experienced manufacturers with high product quality adhere to strict quality control processes to meet – and exceed - the requisite standards. These teams typically have rigorous quality training and dedicated professionals in place to ensure quality standards are being met during machining and fabrication. These measures lead to a higher level of quality control that results in more consistent and elevated product quality – as well as a healthier bottom line and happier customers. At ABS, we are an ISO9001:2015 registered company. In addition, our Heavy Fabrication is a full-service facility certified to CSA47.1 (AWSD1.1) and ASME Boiler Vessel B31.1 and 31.3 standards. Our welders are certified by CWB/AWS and ASME, and are fully trained on flux-core, gas metal, submerge arc, tig and stick electrode welding techniques.
Looking for a machine shop with a robust, mature quality control program?
Contact the team at ABS to learn about our commitment to quality and our proven methods.
- Thorough and Frequent Measurements and Inspections: it is no surprise that inspections are an integral aspect of quality control and a best practice for manufacturers. Quality inspections consist of checking, measuring, and testing parts at predetermined checkpoints along machining and fabrication processes, and comparing the results against specific requirements to ensure compliance. Frequent and routine quality measurements and inspections allow off-spec and defected products to be identified earlier, improving operations efficiency and reducing costs. Over time, data collected during quality inspections can be used to develop trends, allowing machine shops to detect areas with on-going quality issues that need to be resolved. Below are a few examples of the types of inspections that may occur during machining and fabrication projects. These are typically a combination of manual inspections by the operator as well as automated measurements. Using the data, process adjustments are made real-time.
- Inspect raw materials before machining and fabrication starts
- Inspect initial equipment set-ups as well as tool or equipment change-outs
- Inspect and monitor equipment during machining operations to detect wear in order to replace tools before parts become out of spec
- Inspect parts after machining and fabrication to ensure the requisite tolerances and specifications are met
- Additional quality control measurements, inspections, and tests may be employed, such as random sampling, depending on the project
- Establish a Culture that Values Quality: costs become exponentially higher the further along in the process a quality issue is detected. Thus, poor quality is often very costly and machine shop personnel need to have a clear understanding of the true cost of inadequate quality control and its impact on the bottom line. Quality control is a team effort, requiring a company culture that values quality and an unwavering commitment from all personnel to achieve high product quality. Teams must identify the root cause of quality issues and not just treat the symptoms of a problem. There are several forms of root cause analysis, including sigma which ABS utilizes; these processes are very effective at identifying and resolving the root cause of an issue to eliminate quality problems at the source. Additionally, manufacturers that excel in quality control possess a strong process discipline that is not found in every machine shop. Quality control and quality assurance are areas where partners, like ABS, stand out from the competition. We don’t just check the boxes when it comes to quality control: quality is engrained in our culture and our workplace.
ABS’ Commitment to Quality
Quality is the key driver for ABS and is an integral part of every process we undertake. As an ISO9001:2015 registered company, our quality policies are constantly upgraded to meet and exceed our customers’ expectations. Our quality team works hand in hand with our manufacturing and engineering teams and is comprised of professionals from several disciplines including:
- Professional Mechanical Engineers
- Yellow Belts (sigma)
- CMM Programmers and Inspector’s
- Professional Material Engineers
- Black Belts (sigma)
- Gauge and Tooling Specialists
Our commitment to quality and maintaining unparalleled facilities is evidenced by our renowned continuous capital reinvestment initiatives, and our use of advanced technologies. From the inception of all programs, ABS quality professionals work closely with each customer to ensure all their unique requirements are met or exceeded. It is this commitment that has positioned ABS as a strategic supplier to leading OEMs worldwide. ABS is proud to be recognized globally with decades of accolades, and continues to embrace customer quality requirements as a fundamental part of the business.
Contact us today to see how we can help with your machining project, or give us a call at 1-844-227-6224.
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