Comparison of door hinge processing methods and quality control methods at home and abroad_Industry 1

Overseas Production Methods and Quality Control for Door Hinges

Door hinges are crucial components of traditional door designs, and advanced foreign manufacturers have implemented innovative production methods and quality control measures to ensure superior hinge performance. These manufacturers utilize door hinge production machines, specifically combined machine tools, to manufacture spare parts like body parts and door parts.

The production machine consists of a 46-meter trough where the material cutting process is automated. An automatic feeding mechanism positions the parts accurately according to system settings, and milling, drilling, and other required processes are performed. The finished parts are then assembled. The secondary positioning of the workpiece reduces errors caused by repeated positioning, ensuring precise dimensional machining accuracy. Moreover, the machine tool is equipped with an equipment status monitoring device. This enables real-time monitoring of equipment parameters that may affect product quality. Any problems that arise are immediately reported and adjusted.

In the hinge assembly area, foreign manufacturers utilize a full opening torque tester. This tester conducts torque and opening angle tests on completed assemblies, recording all the data. This allows for 100% control over torque and angle, ensuring that only parts that pass the torque test proceed to the pin spinning process. The pin spinning process completes the final assembly of the door hinge, and multiple position sensors are employed during the swing riveting process to detect parameters such as the diameter of the riveting shaft head and the height of the washer. This ensures torque requirements are met.

Domestic Production Methods and Quality Control for Door Hinges

In comparison, domestic production methods for door hinges involve the purchase of cold-drawn plow steel, followed by multiple machining processes such as cutting, polishing, deburring, flaw detection, milling, drilling, and more. Once the body parts and door parts are processed, they are pressed together with the bushing and pin for final assembly using equipment like sawing machines, finishing machines, magnetic particle inspection equipment, punching machines, high-speed drilling machines, and powerful milling machines.

For quality control, operators adopt a method that combines process sampling inspection and operator self-inspection. They utilize various inspection tools such as clamps, go-no-go gauges, calipers, micrometers, and torque wrenches to conduct routine inspections. However, this inspection process is time-consuming and results in a heavy workload, mainly consisting of post-inspection inspections. This has led to frequent occurrence of batch quality accidents. Table 1 below shows the quality feedback of the last three batches of the door hinge type obtained from the OEM, highlighting the inefficiency of the current quality control system and low user satisfaction.

Improving Door Hinge Production Process and Quality Control

To address the high scrap rate and improve the efficiency of the quality control system, several areas will be analyzed and improved:

1. Analyzing the machining process of door hinge body parts, door parts, and the assembly process to evaluate the current process and quality control methods.

2. Applying statistical process control theory to identify quality bottleneck processes, proposing rectification plans for the door hinge production process.

3. Revising and enhancing the current quality control system.

4. Utilizing mathematical modeling to predict the size of door hinge process parameters, applying quality control theories to improve production processes.

Through comprehensive research in the mentioned areas, the aim is to enhance the efficiency of quality control and provide valuable insights for similar enterprises. AOSITE Hardware, always prioritizing customer satisfaction, is committed to providing excellent products and efficient services. With years of experience, AOSITE Hardware holds a leading position in hinge manufacturing. Innovation is at the core of the company's R&D approach, enabling continuous improvement in production technology and product development. Advanced production equipment, superior production lines, and rigorous quality assurance systems guarantee exceptional product quality. AOSITE Hardware's dedication to technical innovation and flexibility in management ensures improved production efficiency. In case of any returns, customers can always contact the aftersales service team for instructions.