Controlled process manufacturing

is required when engineers determine that there are characteristics critical to the performance of a part that are difficult or impossible to define for practical inspection purposes. Stresses created during the production process can cause failure of the product during use. When these stresses cannot be detected without extremely expensive methods (or without destroying the part), the engineers may find it cost-effective to exercise control over production by working with the production team to define fixed manufacturing processes that demonstrate the ability to consistently produce the necessary characteristics of a part that will not fail.

To address this, aerospace manufacturers must implement robust quality control measures. These include rigorous testing, documentation, and traceability throughout the production process. By adhering to approved methods and closely monitoring any deviations, they can ensure that modifications do not compromise the final product. Additionally, collaboration between engineering, production, and quality assurance teams is essential to maintain alignment and prevent unauthorized alterations.

controlled process manufacturing (1)

Nexus Manufacturing can work with your engineers to develop and document a method for controlled process manufacturing, detailing the operation sequence, equipment, tooling, machine parameters (speeds & feeds), inspection, & control techniques. Process definition will include sufficient detail to provide the controls necessary to be effective. These methods can be verified, approved, and audited by your team and your customer.

Once approved, the process will be identified as a “Fixed Process”. Operations and inspection documentation will be labeled with an identifier similar to: “No changes to this process are permitted without prior, written customer approval.” Or other identifiers as required by your team or your customer. Identification of each part produced shall be traceable to the approved fixed process document. Nexus Manufacturing then controls the method of manufacture or repair to remain in compliance with the fixed process document. Employees are trained to ensure compliance with fixed process controls.

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