Manufacturing

Each and every complex step necessary to manufacture brake rotors and drums of the finest quality is undertaken in our TUV ISO/TS16949 : 2002 certified facility.

 

The TUV ISO/TS16949 : 2002 certification was developed by the global automotive industry to achieve world-class level of product quality, productivity, competitiveness and continual improvement.  It defines the quality system requirements for use in the automotive supply chain and is globally acknowledged by all original equipment car manufacturers.

 

Manufacturing Management System

GREN Machinery believes that a product is only as good as it was manufactured.   This is why we utilize the strictest quality manufacturing management system, and are constantly improving upon our processes and manufacturing capabilities.

 

Statistical Process Control (SPC)

Statistical Process Control (SPC) is the application of statistical methods to the monitoring and control of a process to ensure that it operates at its full potential to produce conforming products.   Under SPC, a process behaves predictably to produce as much conforming product as possible with the least possible waste.

 

Much of the power of SPC lies in the ability to examine a process and the sources of variation in that process using tools that give weight to objective analysis over subjective opinions allowing the strength of each source to be determined numerically.  Variations in the process that may affect the quality of the end product or service can be detected and corrected, thus reducing waste as well as the likelihood that problems will be passed on to our customers.

 

With its emphasis on early detection and prevention of problems, SPC has a distinct advantage over other quality methods, such as inspection, that apply resources to detecting and correcting problems after they have occurred.

 

GREN Machinery uses SPC not only to reduce waste, but to also help with the reduction in the time required to produce our products from end to end.  This is partially due to a diminished likelihood that the final product will have to be reworked, as well as a result of using SPC data to identify bottlenecks, wait times, and other sources of delays within the process.  Process cycle time reductions coupled with improvements in yield have made SPC a valuable tool from both a cost reduction and a customer satisfaction standpoint.

 


 

Process Capability Study (PCS)

Process capability is a statistical measurement whose purpose is to demonstrate whether or not a specific manufacturing process is feasible and sustainable.  This measurement process relies heavily on the use of graphs.   By undergoing this strict evaluation, GREN Machinery can learn all the features of a product and can then decide whether to continue with production, change the specifications for the proposed product or cancel the project.

 

Just because a product can be made, doesn't mean that it can continue being produced well.   Determining this is another factor in the process capability study.  Many variables come into play, such as the wear and tear on the machinery that will create the product and the quality of the raw materials to be used.  All of the variable factors are input into specialized software to determine if the manufacturing process is sustainable and what to expect of the final outcome.

 

The result of a process capability study is the total evaluation of the potential product.   Both negative and positive features of the product will be brought to light and may result in presenting possibilities that weren't previously considered.  An entirely new design may be proposed with the potential of providing a more efficient product than originally contemplated, or we may be saved from producing a poorly designed product that is in constant need of revision.

 

GREN Machinery analyzes the data from the completed Process Capability Study to numerically understand where costs will be while improving quality thus providing the maximum value of our products.

 


 

Fail Mode & Effects Analysis (FMEA)

A fail mode and effects analysis (FMEA) is a procedure in product development and operations management for analysis of potential fail modes within a system for classification by the severity and likelihood of the failures.   Successful FMEA activities help GREN Machinery identify potential fail modes based on past experience with similar products or processes, enabling us to design those failures out of the system with a minimum of effort and resource expenditure, thereby reducing development time and costs.

 


 

Tracking Ability (TA)

Each brake rotor and drum that is produced within a GREN Machinery factory is stamped with a unique GREN product code.  This information, in addition to providing us the ability to track any given product going back as far as seven (7) years, also includes discard dimensions.   This information provides key support to the Fail Mode and Effects Analysis (FMEA), while the discard dimensions provide the installer an effortless way to determine when replacement is necessary.