At OTS turbo, ensuring high-quality production of compressor wheels is crucial to delivering exceptional performance for our customers. To achieve this, we meticulously document each stage of the quality check process to maintain transparency, precision, and control over the manufacturing process. Here’s an overview of our quality documentation procedure, highlighting the key stages and methods.
1. Defining Key Quality Metrics
a. Special Characteristics and Specifications
- Each compressor wheel component has critical features that need to meet strict tolerances, such as inner hole diameter, measured to an accuracy of +0 -0.008mm. These specifications are established during the design phase and are integral to product performance.
b. Tolerance Requirements
- Tolerances are predefined for each critical characteristic, which ensures that parts remain within acceptable performance limits. These tolerances are documented in the product specifications and referenced during each quality inspection.
2. Inspection Methodology
a. Instruments Used
- We rely on advanced precision tools, such as image measuring instrument, which capture highly accurate measurements to ensure compliance with specifications.
b. Inspection Frequency
- First and Last Piece Inspection: At the start and end of every production batch, we conduct a thorough inspection of the first and last pieces produced. This helps ensure the entire batch’s quality meets the necessary standards.
Batch Number | First Piece Thickness | Last Piece Thickness | Tolerance Range (0.8 ± 0.1mm) |
Batch#1 | 0.79 mm | 0.81 mm | Within Tolerance |
Batch#2 | 0.82 mm | 0.80 mm | Within Tolerance |
3. Process Control and Documentation
a. Operator and Inspector Sign-Off
- For every inspection, both the operator and inspector are required to sign off on the quality records, confirming that the product meets the standards. This dual verification system enhances accountability.
b. Data Logging
- We use a digital tracking system that logs all inspection data in real-time. Each measurement is stored for analysis, enabling us to generate detailed reports for internal reviews or customer validation.
| Date | Part ID | Measurement | Inspector | Operator | Production Line |
| 2024/10/14 | CW-101 | 0.82 mm | Inspector A | Operator B | Line 2 |
| 2024/10/15 | CW-102 | 0.79 mm | Inspector C | Operator D | Line 1 |
4. Additional Quality Check Details
a. Process example1:Back Machining
- Key Characteristics Control (KCC): For critical dimensions such as inner hole diameter, the quality check ensures these parameters are within strict tolerances.
- Measuring Instruments: Various tools like the air micrometer, image measuring instrument, digital caliperare used for precise measurements.
| Sample of Measured Parameters: | ||||
| Characteristic | Tolerance | Instrument Used | Frequency | Inspector |
| Inner Hole Diameter | Φ11.997–Φ12.003 mm | Air micrometer | 1 per batch | Inspector A |
| Back Disk Thickness | 0.8 ± 0.1 mm | Image measuring instrument | 1 per batch | Inspector B |
| Outer Diameter | Φ12.007 mm | Digital caliper | Random | Inspector C |
| Notes: | ||||
| 1. Measurements are taken at least 5 times, with every 2nd measurement logged. | ||||
| 2. First and last piece inspections are mandatory, with adjustments made if deviations are detected. | ||||
b. Process example 2: Wheel Baldes Machining
- Surface Roughness: This is checked to ensure a smooth finish that will not negatively affect performance, using Ra parameters such as Ra ≤ 0.8.
5. Continuous Improvement
a. Trend Analysis
- We perform continuous trend analysis to spot any minor deviations before they become significant issues. By monitoring production data, we can proactively address any concerns in material quality or process stability.
Conclusion
Our comprehensive documentation process for compressor wheel production ensures that each part meets the highest standards of quality. By leveraging precise measurement tools, data tracking, and advanced reporting methods, we maintain stringent control over every aspect of the production cycle. This thorough approach guarantees that customers receive products that perform reliably and consistently.
