Quality You Can Count On
When you’re ordering custom-manufactured components, quality isn’t something you should have to worry about. At Falcon Industries, we build quality into the process from the time materials arrive at our facility through the final inspection and shipment.
Our team follows established inspection procedures throughout production, verifying materials, dimensions, and workmanship at every stage. We document inspection results for every job, providing our customers with confidence that the finished product meets all specified job requirements before it arrives at their shop.
Built to Your Requirements
Every project starts with understanding exactly what the customer needs. We regularly work from customer-supplied specifications and drawings, which may incorporate industry standards such as CEMA, ANSI, or ASTM.
For example, customer drawings may include AWS or ISO weld symbols, CEMA standards for items such as bolted connections and end lugs, or specific material requirements identified by ASTM code. We follow these requirements as part of the manufacturing process.
Some customers also require material certifications or mill test reports (MTRs). We can provide this documentation upon request to meet specific customer requirements.
Quality Checks from Start to Finish
Quality is also in the quoting process to make sure the drawings are accurate, and we agree to all aspects. We will always get clarification from our customers for any missing or misunderstood information, that way we can offer the most accurate quote
- Incoming materials: We check material size and quantity against the purchase order and review MTRs when required. We reject material that doesn’t meet specifications.
- Initial inspection: The department supervisor reviews the job before production begins.
- In-process inspections: Our team checks the work as production progresses to catch issues early.
- Final inspection: Before shipment, the supervisor verifies required measurements and tolerances and signs off on the job.
- Documentation: We complete an inspection report for every job using tools such as calipers, tape measures, and gauges. We provide inspection records to customers upon request.
The Right Material for the Application
Choosing the right material can directly affect how a component performs and how long it lasts. We source materials according to customer requirements, including specific material grades and domestic material requirements.
We control our inventory by material type and, when applicable, by heat number for plate and sheet. We work with a variety of material distributors rather than relying on a single source, allowing us to source the material that best fits each project’s requirements.
When customers require traceability, we can obtain the necessary information from our vendors.
We also consider how a component will be used when material selection is part of the conversation. For applications involving significant wear, for example, we may recommend an abrasion-resistant material when appropriate. The goal is not simply to manufacture a component that meets the drawing, but to ensure the material meets the application’s demands. We are familiar with a variety of materials, and with our ability to form those materials. We can discuss alternative materials to meet form, fit and function.
Proactive Quality Management
As an employee-owned company, we take pride in the work we produce—and that means taking quality seriously from the start. We build inspections into the manufacturing process to catch non-compliance issues early and address them before a product leaves our facility.
If something does go wrong, we don’t just fix the immediate problem and move on. Our Non-Conformance Report (NCR) process helps us understand what happened, identify the root cause, and put corrective actions in place to help prevent the same issue from recurring.
For us, quality is an ongoing responsibility. We continually look for ways to improve our processes and make sure our customers receive products they can count on.
Quality That Supports Your Production
For our customers, quality is ultimately about more than passing an inspection. It means receiving components that meet job requirements and perform as expected in the field.
From incoming material checks and in-process inspections to final sign-off and non-conformance procedures, we take a consistent, practical approach to quality. Our goal is to manufacture the right product, verify the work along the way, and address issues quickly when they arise.