Built-In Quality: How Simtek Uses In-Process Inspections to Keep Standards High

High-fidelity simulated avionics don’t happen by accident—they’re the result of disciplined processes, controlled workflows, and constant verification.

At Simtek, quality isn’t just a final step at the end of the line. We build it into every stage of what we do by incorporating in-process inspections at every level—from raw material and machining to wiring, assembly, and final test.

Our goal is simple:

Conforming parts, consistent builds, and the highest quality on every shipment.

Quality Starts Before the First Part Is Built

It begins with engineering and planning.

Our teams verify:

• Customer drawings, requirements, and specifications

• Internal models and prints for form, fit, and function

• Approved materials, hardware, and processes before work starts

By catching issues early in the design and planning phase, we reduce rework, delays, and nonconformities downstream.

In-Process Inspections in Machining & Fabrication

In our machine shop, precision parts are checked as they’re being made—not just when they’re finished.

We incorporate:

• Dimensional checks during production runs

• Verification of critical features like hole patterns, depths, and alignment

If something drifts out of tolerance, we catch it quickly—before it moves into wiring, assembly, or paint. That means conforming parts are the only parts that move forward in the process.

Wiring & Assembly With Built-In Checks

As panels, displays, and instruments are wired and assembled, we include multiple layers of in-process inspection, such as:

• Connector and pinout verification

• Visual checks for strain relief, routing, and workmanship

• Continuity tests and basic functional checks on subassemblies

These inspections ensure that when assemblies reach final test, they aren’t hiding wiring issues or assembly defects that could have been prevented earlier.

Finishing, Marking, and Final Details

Even in finishing steps like paint and laser engraving, we maintain strict quality controls:

• Color, finish, and texture are checked against approved standards

• Legends and markings are verified for accuracy, alignment, and readability

• Cosmetic standards are monitored so hardware not only works right, but looks right in your simulator cockpit

Every detail contributes to the overall fidelity of your training device.

Final Inspection on Top of In-Process Control

By the time hardware reaches final inspection, it has already passed multiple in-process checks. Final inspection then:

• Confirms dimensions, labeling, and configuration

• Verifies electrical performance and functional behavior

• Ensures all customer-specific requirements and documentation are satisfied

Because we’ve controlled quality at every step, final inspection becomes a confirmation, not a discovery of problems.

Why In-Process Inspections Matter

In-process inspections help Simtek:

• Prevent defects, rather than just detect them at the end

• Ensure only conforming p

  arts move from one stage to the next

• Maintain a consistent level of high quality across all programs and platforms

For our customers, that means:

• Fewer surprises

• More predictable lead times

• Hardware that arrives ready to integrate and ready to train

At Simtek, quality isn’t a department—it’s a habit. By incorporating in-process inspections at every level, we keep our standards high and our parts conforming, so your simulated avionics deliver the reliability and fidelity your training programs demand.