Committed To Delivering Consistently High-Quality Parts

Unlike traditional production methods, Zonze's on-demand, customized high-mix, low-volume manufacturing services offer design flexibility that mass manufacturing cannot. Additionally, the processes, tooling, and materials for low-volume parts are often less standardized than those for mass-produced parts. This is why quality assurance is essential at Zonze and is one of the primary benefits we offer our customers.

At Zonze, we guarantee that you will receive high-quality parts with consistent specifications every time. This consistency is achieved through our stringent quality control measures throughout the manufacturing process, utilizing state-of-the-art inspection equipment operated by highly skilled technicians. Discover how Zonze's quality control ensures you receive superior, consistent parts that meet your precise specifications.

Optimizing Part Design to Eliminate Part Defects from the Beginning

At Zonze, quality assurance and risk control are integrated into every step of the manufacturing process. Once an order is placed, our skilled engineering team conducts a comprehensive DFM (Design for Manufacturing) analysis of your part design within 24 hours. Our DFM analysis leverages advanced technology and expertise, setting our manufacturing services apart from traditional production methods. By incorporating our DFM analysis early in your product development, you can enhance part manufacturability, minimize manufacturing risks before mass production, and expedite your product's time to market.

Ensuring Quality Before Production Begins

Additionally, multiple inspections are carried out throughout the manufacturing process to ensure the highest quality standards. Before production starts, we conduct Incoming Quality Control to verify material qualification from the outset. At Zonze, all material suppliers must provide a Certificate of Analysis (COA) to ensure the incoming materials meet your specifications. We employ advanced XRF analyzers to detect the elemental composition of materials, confirming their quality. Furthermore, we use an Infrared Carbon & Sulfur Analyzer to measure carbon and sulfur content, assessing the performance of metals.

Performing Quality Control for Ongoing Manufacturing

Before proceeding with full production, we conduct First Article Inspection (FAI) to ensure parts comply with specifications. We use industry-standard equipment like calipers and pin gauges for basic dimensions. To minimize temperature-induced measurement variations and achieve higher precision, we house additional metrology equipment in our climate-controlled metrology room, including a world-class coordinate measuring machine (CMM). The CMM can be programmed with CAD file coordinates, allowing it to accurately measure parts' critical dimensions. We provide detailed FAI reports for your review.

Furthermore, we implement In-Process Quality Control during production to monitor and correct any issues. We use statistical and periodic sampling to ensure parts conform to specifications.

For Outgoing Quality Control, rapid and accurate full-dimension measurements of each part are crucial. Our climate-controlled metrology room also features a Flash Measuring Machine for quick batch measurements and an Automatic Image Measuring Instrument for fast, precise 2D measurements. Additionally, our 3D Scanner provides full-dimensional evaluation and variance identification. This advanced equipment ensures all final parts are inspected efficiently and accurately.

Quality Control for Different Manufacturing Processes

While quality control systems for CNC machining, injection molding, and urethane casting share similarities, each service also has unique quality measures. For injection molding and urethane casting projects, we optimize and document the ideal setup process, ensuring consistent parameters and procedures for every run of your mold. Our general tolerance for CNC machining adheres to DIN ISO2768 medium (fine), providing specific guidelines to ensure high precision and quality.

If you visit our manufacturing floor, you'll notice its well-organized and well-equipped setup, further highlighting our commitment to quality control.

Additionally, a Certificate of Conformance is shipped with your products for your qualifications and final review. These quality assurances help eliminate mistakes and deliver consistent low-volume parts that meet, and often exceed, your quality expectations.