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| Our compressor
quality begins with the raw material and core receiving processes at our
warehouse in Grapevine, Texas. Aided by voice-recognition software, every
core is checked for condition and inventoried accordingly. All inbound raw
material goes through a quality assurance process. From this point, the
inventory level of all material is controlled using a kanban system. Throughout
the implementation of kanban, just-in-time and other lean manufacturing
techniques, Murray has been able to produce vastly larger quantities of
compressors in the same amount of space. |
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Needed cores are then shipped
to our manufacturing plant, also located in Grapevine. Before cores enter
the production area, they are cleaned in a water-based steam-cleaning tunnel
to reduce the amount of contamination entering the production area. Murray uses bio-compatible detergents for virtually all cleaning processes. This water is treated to remove contaminants in Murray's own on-site water treatment facility. Compressors are painted with water-based paint, thereby eliminating the release of harmful petroleum-based fumes. |
| After steam cleaning, the cores are completely
disassembled, including all sub-assemblies. All components slated for re-use,
are inspected at every stage of the disassembly and assembly processes.
Production employees are empowered to scrap any suspect component. Re-usable
components are then cleaned in vibratory cleaners. Murray replaces 100 percent of most internal compressor parts including shaft seals, gaskets, o-rings and bearings. Many compressors also receive new pistons, piston rings, ball shoe disks, noses, rear heads, swash plates, as well as other components. All materials are HFC134a-compatible, ensuring that all Murray compressors will function in vehicles serviced with either CFC12 or HFC134a. |
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One of Murray's greatest strengths
is the capability to machine castings and forgings. Murray machines a myriad of internal components made from its own dies and molds: pistons, yokes, noses, rear heads and cylinder bodies. |
| These castings are machined on any one of
15 computer-numeric-controlled lathes and mills. Statistical process control is automated with a networked Rockwell Allen-Bradley Datamyte system. All components are machined to original equipment dimensions and surface finish grades. |
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After machining, boring, lapping,
grinding and/or honing, all components, (including those that are new) go
through another cleaning operation before the assembly process. After assembly,
every compressor is tested for sound level, vacuum and pressure retention
and any leakage using programmable, automated test stands, pressure decay
and mass absorption spectrometers. Compressors that pass these tests go
through a final steam cleaning operation before painting and packaging. |
| Random life testing is conducted on an ongoing
basis. Compressors are tested for hundreds of hours on fully automated life
test stands, equipped with electronic data-acquisition devices which simulate
driving conditions over the equivalent of 50,000 and 100,000 miles. |
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Testing doesn't stop there. All of our units are 100 percent leak checked prior to shipping and then shrink wrapped within the box to protect the unit from damage during handling. |
| It is Murray's strengths in engineering,
design and machining that enabled it to become the first and only aftermarket
climate control supplier to produce a 100 percent new compressor. Murray
produces new replacement compressors for Ford FS6, Chrysler C171, and GM
applications. Other new compressors will be offered in the future. |
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Copyright © 2005 Four Seasons, Inc., A Division of Standard Motor Products |
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