Commitment to Quality

Our Quality Statement:

Estes Design and Manufacturing, Inc. is committed to employing people of high character, creative, innovative thinking, state-of-the-art technology, and continuous improvement to maintain an effective quality management system and profitably produce fabricated sheet metal products compliant with requirements and to a level of satisfaction preferred by our customers.

 

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Quality Certifications

Our ISO certifications help us to outline and maintain a framework for improving our Quality Management System (QMS).

Highlights of Our Quality Management System

  • ISO 9001 and ISO 13485 certified
  • Part-to-file 2D blank inspections with Fabrivision inspection machine
  • Part-to-CAD 3D part inspections with Romer Absolute arm and RS6 Laser Scanner
  • Operation-specific inspection plans for all production parts
  • Visual audit sampling for all production parts
  • Process and equipment validations
  • Vendor quality monitored
  • Quality communication with team members during shift meetings
  • Continuous Improvement ideas during shift meetings

Quality Conscious

In the world of sheet metal fabrication, we understand that speed and quality mean everything to our customers. Learn more about how our state-of-the-art equipment helps us achieve high-quality parts by taking a virtual tour.

Let Estes' commitment to high-quality fabrication take your project to the next level.

Processes & Standards

Inspection Process

Our inspection process begins with our experienced setup personnel. With each process setup the part is first verified by the setup operator against the prescribed inspection instruction. Once the setup operator has a part believed to be within specification, the setup part is taken to the inspection area where a dedicated shift inspector checks the part for setup approval. In-process inspections are sampled through the run, and final inspection and a visual audit takes place once all operations are complete.

Quality Standards

Estes is a precision fabricator and our state-of-the-art CNC fabricating equipment and creative and innovative thinking allow us to perform to most tolerances with a high level of consistency, accuracy, and repeatability. Factors such as part design and complexity, material selection, tooling, and production processes all impact dimensional tolerances, but our general operating tolerances are +/-.005” for a cut/punch feature size, +/-.010”  cut feature to feature, +/-.015” feature to formed edge, and +/-.030” form edge to form edge.

How do we ensure the quality of our fabrication work?

Step 1

Quality begins in planning, our estimators and project managers review customer prints and specifications to assure product requirements are understood.

Step 2

The team designs a process flow capable of meeting the customer product requirements. Utilizing controlled programs, routings and inspection plans, the front end creates the documentation and instruction necessary to translate customer requirements to the manufacturing process.

Step 3

Our experienced production and inspection teams execute the established process flow, using the prescribed programs and inspections in order to assure compliance and satisfaction of the customer requirements. Along the way, team members at every level offer suggestions for correction and improvement of process performance in the fabrication of customers’ product.

Quality Management Tools & Equipment

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Hexagon RS6 Laser Scanner

New to Estes in 2020 is the Hexagon RS6 Laser Scanner and Romer Absolute Arm. Introduced in late 2019, the RS6 Scanner is a game changer in laser scanning with the introduction of its blue light laser with SHINE technology that allows nearly every surface type to be properly scanned without altering scanner exposure. This advancement assures more accurate scans and reduces the time and frustrations associated with changing red line scanner parameters or spraying parts. Additionally, Estes has coupled this technology with the power of PolyWorks Inspector, the market leader in 3D metrology.

We believe the addition of the Hexagon Absolute arm with the RS6 Laser Scanner powered by PolyWorks supports our quality policy tenant of employing state-of-the-art technology and will further facilitate our creative, innovative thinking and continual improvement.

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FabriVision Scanner

Our Fabrivision scanner helps us ensure the quality of part blanks we fabricate, utilizing cameras to capture the cut perimeter and feature edges of a blank as the scanning bridge passes over the part. These scanned perimeter and feature outlines then are compared back to the CAD-generated flat DXF of the part blank, generating a detailed color map indicating the conformance of the part edge versus the engineered blank. This quality step assures our team that the blanking operation setups have been executed correctly, ensuring the quality and accuracy of punched and laser cut parts before they are moved on to forming operations.