Designing the Manufacturing Route
01
UNDERSTAND THE COMPONENT
Our process begins by identifying the component. Backed by solid experience, this identification provides us with a clear baseline regarding its intended functions, operating environment, operational stresses, and typical failure modes.
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This engineering awareness allows us to better comprehend technical instructions by analysing the underlying reasons behind them, helping us apply sound judgment to address even those aspects not explicitly covered by the initial specifications.
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As a practical example, consider a specification requiring minimum post-heat-treatment mechanical properties for a forging.
Knowing that the forging is intended for a rotating component, we coordinate with the heat treater to ensure it is positioned centrally within the furnace’s radiant heating zone—even when not explicitly requested.
02
ENGINEER THE PROCESS
Starting from the identified required technologies, an initial complete manufacturing process is developed based on the intended contribution of each phase.
We then evaluate their integration and mutual interaction to identify potential criticalities early on, so defining the necessary validation points.
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Since every component is unique, an effective physical simulation of the process is not feasible; instead, we perform a comprehensive loop test analysis of the overall process layout to verify if the configuration ensures stable reliability. With a positive outcome, the process is consolidated.
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If any inconsistencies emerge, we trace the specific issue back to its source to understand the underlying causes and resolve the initial fault, before restarting the analysis to verify the update.
03
DELIVER AN INSTALLATION-READY COMPONENT
Once production begins, the outcome of each validation point confirms the correct completion of its corresponding manufacturing stage.
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This entire sequence can be documented and shared with the customer through agreed documentation, with validation points jointly agreed upon.
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Because these controls and documentation are defined together, their results can be shared and validated by the customer at every stage, leaving only the last step to be verified during the incoming material acceptance when the component reaches the customer’s plant.
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FROM REQUIREMENTS TO THE COMPONENT
1. COMPONENT CLASSIFICATION
2. EXPLICIT REQUIREMENTS
3. INITIAL ROUTE DESIGN
4. FEASIBILITY REVIEW & REFINEMENT
5. CUSTOMER ENGINEERING ALIGNMENT — IF REQUIRED
6. FINAL MANUFACTURING ROUTE
7. MATERIAL PROCUREMENT & VALIDATION PLANNING
8. MANUFACTURING & PHASE VALIDATION
9. FINAL VALIDATED COMPONENT
