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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, Trumark
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. Trumark uses bio-compatible detergents for virtually all cleaning processes. This water is treated to remove contaminants in Trumark's own on-site water treatment facility. Compressors are painted with water-based paint, thereby eliminating the release of harmful petroleum-based fumes. |
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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. Trumark 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 Trumark compressors will function in vehicles serviced with either CFC12 or HFC134a. |
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One of Trumark's greatest strengths
is the capability to machine castings and forgings. Trumark machines a myriad of internal components made from its own dies and molds: pistons, yokes, noses, rear heads and cylinder bodies. |
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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. |
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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. |
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It is Trumark'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. Trumark 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 Trumark, Inc., A Division of Standard Motor Products |
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