Quality Inspection & Documentation

Billet weight, forging temperature, die condition, forged weight, heat treatment hardness and machined dimensions each have their own check frequency and record. Catching drift at the forging stage costs a die adjustment; catching it at final inspection costs the whole batch.

• Billet weight and temperature checks
• Forged weight sampling per shift
• Hardness verification after heat treatment
• Final dimensional layout

We prepare PPAP submissions, control plans, PFMEA, process flow diagrams, gauge R&R studies and first article inspection reports. For export shipments, the pack typically includes material certificates, heat treatment charts, dimensional reports and NDT certificates under one batch reference.

Every batch carries its heat number from the steel supplier through forging, heat treatment, machining and packing. If a question arises after delivery, we can reconstruct exactly which billet lot, which die, which furnace charge and which machining setup produced the part in question.

Quality on a forging line is decided while the parts are being made, not at the end. Each stage has its own check, frequency and record, because catching drift at the forging stage costs a die adjustment while catching it at final inspection costs the batch.

Inspection level should follow consequence. Safety-critical parts — steering, braking, suspension, lifting — receive 100% magnetic particle inspection and full dimensional verification. General engineering parts are inspected to a documented sampling plan agreed with the customer. Whichever applies, the gauges themselves must be trustworthy: measuring equipment is calibrated, and for automotive work, measurement system analysis establishes that the gauge and operator can actually discriminate the tolerance being measured.

• 100% inspection where failure risks life
• Documented sampling plans elsewhere, agreed in advance
• Calibrated gauges with recorded calibration status
• Measurement system analysis for automotive characteristics

Every batch can be released with a documentation set tied together by its heat number: material test certificate, heat treatment chart, hardness results, dimensional report, NDT certificate where applicable, and a certificate of conformity. For automotive customers we prepare full PPAP submissions including control plan, PFMEA, process flow and capability studies. For export orders the pack also carries the commercial and packing documents. See forging quality documents.

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