Stage 1:
Contract Review & Planning
When we receive a PO, our first step is to review terms & conditions, quality requirements, and specific DFAR requirements (if any), along with any attached drawings or models (see diagrams 1,2 and 3). This information is utilized to create and populate job traveler details including customer, part #, rev, quantity, due date, all process steps required for the job, and any outside process vendors.
Once the traveler has been created, we order materials, confirm lead times, schedule the team and machine resources, and order any special QC inspection and machining tools.
Communications Pod, Horizontal View.
Communications Pod, Angled View.
Stage 2:
Design for Manufacturability Review
For any new parts Hi-Tech is awarded (versus repeat parts), a review team including programmers, machinists, production supervisors, quality control and senior leadership comes together to objectively review the new part and aggregate our team’s design for manufacturability feedback.
This feedback assesses the original drawings, all necessary tolerances & features, and expected operations to: a) identify items that need clarification, b) opportunities to optimize or accelerate the machining approach, and c) suggest adjustments to part specifications to optimize machining and application requirements.
A summary memo is shared both internally and with the customer for insight & feedback, creating an open dialogue around alternate recommendations and production next steps — and significantly improving the reliability of our delivery timing
Diagrams and images are an example of the production process relating to Communications Pods for NAWC-WD. For more information see our case studies.
Stage 3:
Modeling & Programming
Our Programmer’s first step is reviewing the part’s model and/or creating a model if one does not already exist. If a model is created internally, it is shared with the customer for confirmation, after which we define the programming approach for roughing, semi-finish, and finish. Tool path verification comes next, along with adjusting run rates & cutting speeds via direct engagement with the Production team. Our Programmers also confirm any special tools which need to be ordered.
The active feedback loop between our Programming and Production teams ensures every part is machined as expected, and Hi-Tech can be proactive with any customer updates and questions.
Custom Fit Rings.
Stage 4:
Production
Our Machinist starts by confirming everything from the setup sheet is ready and available, including necessary tools, tool holder extensions, and accessories to run the part. The program, tools, and materials are loaded onto the machine, and the part starts running.
A major milestone is achieved each time our Machinist signals the part is ready for first article inspection following each operation.
Pod during production, internal view.
Stage 5:
Outside Process/Finishing
In parallel to Hi-Tech’s programming and production work, our Operations team schedules and confirms dates & delivery timing for any outside processes (e.g. chem-film, anodize, paint, etc.).
A receiving inspection is conducted on every part received back from an outside vendor to confirm the finishing process meets specifications and requirements.
Stage 6:
Assembly
Our Assemblers collect all necessary hardware (e.g., helicoil, inserts, rivets, etc.), along with the part’s drawing, and assemble the hardware per the specification sheet. This process also includes prep for final inspection (e.g. part stamping).
Pod before dip-braze and paint.
Finished Communications Pod, lateral view.
Stage 7*:
In-Process QC & Final Inspection
In-process inspections facilitate a continuous review of GD&T for every part to ensure alignment to drawing specifications. If at any point, a first article is out of tolerance, the program is adjusted and the part is run with a new first-article and verified before moving forward.
At final inspection, our QC team ensures the finished product meets all GD&T specifications, and builds a complete CoC (certificate of conformance) package including any first article inspection (AS9102) reports, dimensional reports, materials certifications incl. outside process certifications, and any non-conformance approvals from the customer along the way. The team uses a CMM and other QC inspection tools to measure and document part specifications, and prep final documentation for customer inspection and final delivery.
Once confirmed, the part and any supporting documentation are delivered to the customer.
*These steps are conducted through-out the programming, production, and assembly processes, and serve as the final quality checkpoints before a part is prepped for delivery.
Ameba Creative Studio