Manufacturing Quality Management

Manufacturing Quality Control

Raw Materials

Supplier

• All RM vendors undergo thorough inspections & QA programs in order to mill our high-standard products
• German made manufacturing equipment

Inspection

• Chemical – Each batch of raw material is sample tested to ensure all chemical ranges exceed API standards
• 100% of sucker rod raw material must pass through EMI for surface inspection
• All rejected materials are returned to raw material mill for scrap

Specification

• Exceed requires tighter specs on raw materials when compared to API
• Exceed focuses on improved grain size and structure to ensure a more durable sucker rod

EMI Machine

• US made rod inspection system
• Same equipment used by inspection companies such as PRO, Tuboscope and TRC
• Exceed is the only rod supplier that has EMI inspect 100% of raw materials

New Facility

• 120,000 Sq ft facility opened in 2015; 150 million ft annual capacity
• Fully integrated manufacturing process, raw material to packaging
• All raw materials and packaged final products are stored inside

Automated Forging

• 7-step forging process with computerized control over temperature and timing of each process
• 100% Automated to reduce human error commonly experienced with manual forging
• Three separate production lines, dedicated to 3/4“, 7/8” and 1” products

Heat Treatment

• Electric oven with precision digital temperature
• Full-body treatment capable of processing products up to 30 ft
• Integrated with both normalized and quenching & tempered process
• Three separate heat treatment lines, dedicated to 3/4“, 7/8” and 1” products

Automated Threading

• Fully automated 5-step rod threading process
• Rotate rollers instead of rod body; which guarantees pin straightness
• Fully-automated process exceeds the capacity of 40 CNC machines at traditional manufacturers

Shot Peening

• New equipment design to ensure consistency
• Removes debris and scale, also creates a compressed surface layer
• Peening pallets are not reused to guarantee consistency
• Digitally controlled spray velocity to further ensure the optimal coverage

Packaging

• All products are coated with protective paint and grease
• Bundle design optimized for container shipping
• All products are stored indoors before shipping

Raw Material Incoming Testing & Inspection

• Dimensional Testing
• Chemical Composition
• Surface Testing – EMI

Manufacturing Process QA Procedures

• Forged Dimensions
• Forging Defect Check – MPI
• Thread Compliance – Go/No-Go

Destructive Testing Verification of Specs

• Tensile, Yield, Hardness
• Torque Strength – PCP applications
• Grain Size, Structure and Uniformity

Final Product Inspection and Testing

• Packaging Quality
• Chemical Samples
• Mechanical Sample

Chemical Composition

Performed by an internal test lab; raw material and final products are sample tested to confirm chemical composition

Tensile Strength Testing

Performed by internal test lab, tensile strength test is the most important QA test process

Hardness Testing

Hardness testing is performed on final product samples to verify specification compliance

Pin Thread Testing

All threads are gauge tested according to API standard

MPI Testing

Magnetic particles are attracted to any forging defects, which are revealed under UV light

Measurement

Dimension measurements are performed at multiple steps in the manufacturing process, from raw material to final products

EMI Testing

Using an EMI machine purchased from the US, defects often overlooked by the human eye can be detected

Coupling Testing

Coupling and other accessories are tested and inspected following the same process