Quality Assurance & Inspection

Operating to AS9100 Rev D means our systems are aligned with the expectations of the aerospace industry. Procedures control how we handle customer requirements, drawings and models, how we review contracts, manage risk, approve suppliers and maintain equipment.

For customers this translates into a consistent way of working, whether the job is a single prototype or a long running production contract. It also means that when you audit us, you find a structure that will be familiar from other aerospace suppliers, with documented processes and clear lines of responsibility.

The same quality framework applies to all of our disciplines, CNC machining, fine limit sheet metal work, turning, waterjet cutting, CAA approved welding, finishing and assembly. This is important for multi process parts where work moves between factories and departments. Every step is covered by the same system.

To support our quality management system we use dedicated inspection tools and software. Core elements include

• Q-Pulse AS9102 inspection management for planning, recording and controlling first article and batch inspection activities
• CRYSTA Apex CNC CMM with scanning, used for prismatic components, complex forms and profiles
• Inspection to GD&T with profile scanning, allowing us to verify geometric tolerances as well as simple linear dimensions
• Microscopic inspection for FOD control, used where foreign object debris and very fine defects are a concern

The CMM and scanning capability are particularly important for our 5 axis machining, fine limit sheet metal and complex fabricated parts, where position, form and profile all matter. Being able to programme and repeat detailed inspection routines gives confidence that parts from different batches and machines meet the same standard.

Microscopic inspection is used on parts and assemblies where contamination and surface condition are critical, for example components for hydraulic systems, fuel and water systems and high value electronic assemblies.

Inspection at GASE starts long before the final release stage. At the front end of a job we review drawings, models and specifications to make sure requirements are clear and achievable. From there, the route is planned with appropriate inspection points built in.

During manufacture we use a mix of operator self inspection, dedicated first off checks and patrol inspection, depending on the risk associated with the part. For multi operation components, inspection is used to control key stages, for example after waterjet cutting, after forming and after critical machining operations.

Final inspection brings these steps together. Using the CMM, manual measurement and visual checks, we confirm that the part or assembly meets drawing requirements and that associated documentation is in place. Where customers require AS9102 style first article inspection, Q-Pulse is used to structure and record the process so that reports are complete and repeatable.

Many of the parts we produce are not simple blocks and brackets. They are complex machined components, thin gauge fabrications or assemblies that combine formed, machined and welded features.

The CRYSTA Apex CMM with scanning allows us to check more than just basic dimensions. We can measure profiles, radii, positional tolerances and 3D surfaces against the model, which is vital for parts such as

• 5 axis machined aerospace components with multiple angled faces
• Specialist machined parts that require folding and complex profile scanning during inspection, as highlighted in our brochure
• Fabricated and machined titanium aircraft parts where alignment between features must be tightly controlled
• Pressurised aircraft boilers and nuclear fire trap assemblies with critical interfaces and fits

By tying CMM programmes back to the original CAD data, we reduce the risk of interpretation errors and make it easier to repeat inspections across batches and over the life of a programme.

For many customers, especially in aerospace and high end electronics, cosmetic standards are almost as important as dimensional accuracy. A part can be nominally correct on a CMM and still be unsuitable if the surface finish or grain direction is wrong.

Our inspection routines take this into account. Visual standards, agreed samples and customer specifications are used to control

• Grain direction and consistency on sheet metal panels and skins
• Blending and appearance of welds on visible fabrications
• Bead blasted and brushed finishes after machining and finishing operations
• Cleanliness after vibratory deburring, bead blasting and ultrasonic cleaning

For parts going into safety critical systems we link surface inspection with FOD control, making sure that no loose particles, swarf or blast media remain in cavities or internal passages.

Quality assurance is not just about proving that a part is right today, it is about being able to show how it was made and checked in the future. Traceability is built into our approach from material receipt onward.

We maintain records for

• Material certificates and batch identification
• Process routes and operation histories across machining, sheet metal, waterjet and welding
• Welder qualifications and weld procedures for CAA approved welded components
• CMM programmes and inspection results
• Cleaning and finishing processes where specific treatments are required

These records are held within our quality management system and can be provided as part of manufacturing data packs where contracts call for that level of documentation.

GASE operates from four factory sites in Crayford, each with its own manufacturing focus but all under the same quality umbrella

• Factory Site 1, fine limit sheet metal work centre of excellence, CAA approved welded components, waterjet cutting and 5 axis milling
• Factory Site 2, 5 axis machining centre of excellence
• Factory Site 3, turning centre of excellence
• Factory Site 4, specialist non metallic machining

Quality assurance and inspection are coordinated across these sites so that a part starting life as a waterjet cut blank in Factory 1, passing through machining in Factory 2 and finishing in Factory 1 again, is treated as a single controlled job.

Shared procedures, common documentation and centralised quality oversight mean that customers see one joined up system rather than four separate factories.

Our quality and inspection capability is designed to support work at every stage of a product’s life. For early prototypes we can work with customers to interpret design intent, agree practical tolerances and develop inspection strategies that make sense for low volumes.

As parts move into pre production and then regular batch manufacture, we refine inspection plans, establish stable processes and lock down CMM programmes and documentation. First article inspection reports can be created and frozen at an appropriate point, then referenced for future batches through Q-Pulse.

For long term programmes, regular internal audits and external surveillance by Bureau Veritas help to keep the system current and effective.

Underpinning the formal systems is a culture that has grown over more than 60 years in precision engineering and fine limit sheet metal work. The company’s heritage with organisations such as Strand Electric, MOD Woolwich Arsenal and Vickers of Crayford has shaped a practical, disciplined approach to quality on the shop floor.

With a workforce of around 65 people across four factories, we place a lot of emphasis on training, cross discipline understanding and clear communication between engineering, production and quality. The aim is that operators, inspectors and managers all have the same view of what “good” looks like for a given part.

Choosing GASE Engineering means your parts and assemblies are produced within an AS9100 Rev D certified environment, using modern inspection tools and managed processes that are appropriate for aerospace, nuclear and high reliability applications.

In practical terms you get:

• A controlled, documented route from raw material to finished assembly
• CMM and profile scanning capability for complex machined, formed and welded parts
• Inspection processes aligned to AS9102 where required
• Strong FOD and cleanliness control for sensitive systems
• Full traceability of materials, processes and inspection results

If you would like to audit our facilities, review our quality procedures or discuss inspection requirements for a new project, the GASE Engineering team will be happy to support you.