The reliability of the crusher parts directly determines the continuous operation capacity of the entire production line and the cost of ore processing. When choosing a supplier with system capabilities, it is necessary to penetrate the surface qualifications and deeply verify its technical accumulation and process control level. The following seven core capability frameworks and twenty executable checkpoints provide a structured evaluation path for procurement decisions.
Core Competence One: The substantive operational depth of the quality management system
Checkpoint 1: Coverage of process certification
While requiring suppliers to provide ISO 9001 certification, it is necessary to demonstrate how their quality management system documents are specifically mapped to the manufacturing process of crusher parts. Check whether the quality manual includes operation instructions for specific processes such as the temperature curve control of jaw plate casting, the dimensional chain analysis of spindle finishing, and the design of quenching fixtures for hammer head heat treatment. The scope of certification should clearly cover secondary categories such as high manganese steel casting, alloy steel forging, and precision mechanical processing, rather than the general “mechanical parts manufacturing”.
Checkpoint 2: Process Capability Index (Cpk) Monitoring mechanism
At the processing site of the cone crusher liner, the size data of three production batches were randomly selected, and the supplier was required to present its Cpk calculation records. The Cpk value of key fit dimensions (such as the installation position of the main shaft and the bearing) should not be less than 1.67, and it is necessary to prove the closed-loop rate of corrective measures taken when Cpk is lower than 1.33. Review the process capability monitoring charts of the past 12 months to verify whether a dynamic early warning mechanism has been established.
Checkpoint 3: Physical isolation for nonconforming product control
Verify the red-marked non-conforming product area at the supplier’s production site, with a focus on checking whether there are dedicated isolation shelves for crusher parts in this area and whether different defect types (cracks, hardness deviations, dimensional deviations) are stored separately. It is required to present the record of the non-conforming product handling process, track the complete circulation documents from isolation, review to final disposal (scrapping, rework), and confirm whether the three steps of “fact identification + cause analysis + measure verification” are strictly followed.
Core Competence Two: Professional precision in materials engineering technology
Checkpoint 4: Technical document system for material traceability
For the jaw plates of the jaw crusher, it is required to provide a complete material passport from the furnace number of the steel plant to the finished parts. The document should include the spectral analysis report of the chemical composition of raw materials, the metallographic structure spectrum (austenite grain size rating at 200 times magnification), and the test data of impact toughness (Ak value at -20℃). Verify whether it uses a spectrometer to re-inspect each batch of materials upon their entry into the factory, rather than relying on the quality guarantee certificate from the steel mill.
Checkpoint 5: Heat treatment process window control
The uniformity of hardness of the hammer heads of hammer crushers depends on the control of quenching cooling rate. The supplier is required to provide the TUS (Temperature Uniformity Test) report of the heat treatment furnace, verifying that the temperature difference between any two points in the effective heating zone does not exceed ±5℃. Check the concentration monitoring records of the quenching medium (polymer water solution or oil) to confirm whether the concentration detection is carried out for each shift, and dynamically adjust the quenching time parameters based on the effective thickness of the parts.
Checkpoint 6: Verification of the applicability of surface strengthening technology
For roller skins subjected to high impact loads, verify the logic of their surface strengthening process selection. The supplier is required to explain the decision-making basis for using boronizing, surfacing hard alloy or shot peening for strengthening, and provide the depth inspection report of the strengthening layer (the boronizing layer should reach 80-120μm) and the bonding strength test (tensile method ≥70MPa). Observe on-site whether the enhanced treatment is carried out in an independent temperature-controlled workshop to avoid cross-contamination that may affect process stability.
Core Competence Three: The ability to achieve the ultimate precision in manufacturing processes
Checkpoint 7: Precision grades of key process equipment
Verify the positioning accuracy and repeat positioning accuracy inspection report of the spindle machining lathe. When the roundness tolerance of the main journal is ≤0.008mm, the radial runout of the main shaft of the processing equipment must be controlled within 0.003mm. It is required to provide the annual accuracy calibration certificate of the equipment and verify whether the calibration institution is a CNAS-accredited laboratory. Observe whether an online measurement system (such as pneumatic measuring instrument) is used for process monitoring at the processing site, rather than relying solely on final inspection.
Checkpoint 8: Traceability control of welding processes
The welding procedure qualification (WPQ) document for the crusher frame must cover all plate thickness combinations and joint forms in actual production. Verify the welder qualification certification records to confirm that each welder’s AWS or EN standard certificate is valid and that the examination items match the current welding tasks. Three welds were randomly selected on site. Ultrasonic flaw detection was used to verify whether the internal quality grade met the requirements of Grade B of EN 1714 standard, and the correspondence between the flaw detection report and the weld number was checked.
Checkpoint 9: Selection and configuration management during the assembly process
The assembly clearance of the eccentric sleeve of the cone crusher directly affects the smoothness of operation. Request the supplier to display its group selection record to verify whether it has divided the spindle and eccentric sleeve into 5 to 7 tolerance zone groups according to the measured dimensions, avoiding maximum physical assembly. Check the temperature and humidity control records of the assembly workshop environment to confirm whether the temperature is maintained at 20±2℃, so as to eliminate the influence of thermal expansion and contraction on precision assembly.
Core Competence Four: R&D response and technological iteration speed
Checkpoint 10: Reverse engineering data integrity
When purchasing non-standard parts, verify their reverse engineering process documents. It is required to provide 3D laser scanning point cloud data, records of the CAD model reconstruction process, and calculation books for the allocation of key dimensional tolerance zones. Verify whether finite element analysis (FEA) is conducted on the reconstructed model to simulate the stress distribution under actual working conditions, and provide an analysis report with a stress concentration coefficient of ≤2.5 as the basis for design verification.
Checkpoint 11: Construction of the Failure Mode Database
Ask the supplier whether they have established a case library for the failure of crusher parts, and require them to show at least 50 historical failure samples of macroscopic fracture surface photos, microscopic scanning electron microscope (SEM) analysis results, and hardness gradient curves. The database should be classified by parameters such as ore hardness (Mohs hardness grade), processing capacity, and service life, and be capable of quickly retrieving failure modes under similar working conditions, providing a preventive basis for new designs.
Checkpoint 12: Rapid prototyping channel capability
Evaluate whether it is equipped with an independent rapid trial production unit, which is physically isolated from the mass production line. It is required to provide the time record from the confirmation of the drawings to the delivery of the first piece. Qualified suppliers should complete the first piece manufacturing of jaw plate parts within 10 working days. Verify whether the trial production unit is equipped with small high-frequency quenching equipment and 3D printing sand mold capabilities to shorten the process preparation cycle.
Core Competence Five: Supply Chain Resilience and Delivery Accuracy
Checkpoint 13: Raw Material safety Stock Strategy
Verify the inventory turnover rate and safety stock level of key raw materials such as high manganese steel and chromium-molybdenum steel. It is required to provide real-time inventory screenshots from the ERP system to verify whether it maintains a safety stock level of no less than 30 days of production consumption and whether it sets warning inventory levels for supply chain disruption risks. Trace the delivery records during the epidemic or periods of sharp fluctuations in raw material prices to verify the resilience of its supply chain.
Checkpoint 14: Secondary control of the heat treatment outsourcing party
If the heat treatment process is outsourced, the CQI-9 (Special Process Heat Treatment System Review) certification certificate of the outsourcing party must be provided, and the supplier is required to conduct on-site audits of the outsourcing party every quarter. Verify whether the audit report includes the calibration records of thermocouples in the heat treatment furnace, the replacement cycle records of quenching media, and the hardness spot-check data. Confirm whether the supplier conducts 100% hardness testing of outsourced parts to verify the quality of incoming materials.
Checkpoint 15: Visual tracking of production plans
It is required to log in to the supplier’s production management system to view the production scheduling status of the crusher parts orders in real time. The system should display the completion percentage of specific processes, the current processing equipment number, the operator’s name and the estimated completion time. Verify whether it has established a production anomaly escalation mechanism. When the process delay exceeds 4 hours, an email warning will be automatically triggered to the senior management.
Core Competence Six: Detection Capability and data credibility
Checkpoint 16: Independence and qualifications of physical and chemical laboratories
Verify whether the supplier’s own laboratory has been accredited by ISO/IEC 17025, with a focus on checking whether items such as metallographic analysis, hardness testing, and impact testing are within the accredited scope. It is required to provide a laboratory quality manual to verify whether the sample retention system is strictly implemented (expired samples should be retained for at least 12 months). Observe whether the laboratory is equipped with standard substances (such as standard hardness blocks) for daily quality control and verify their interim verification records.
Checkpoint 17: Process coverage of Non-destructive testing (NDT)
The main shaft of the crusher must be inspected by both UT and MT methods. The DAC curve calibration record of the ultrasonic flaw detector is required to be provided to verify whether its detection sensitivity complies with the requirements of GB/T 7734 Class B. Verify the quarterly detection records of white light illuminance and ultraviolet irradiance of magnetic particle flaw detection equipment to ensure that the defect identification environment complies with the standards. Spot check the flaw detection report on site to verify whether the schematic diagram of the detection area accurately marks the detection path and probe number.
Checkpoint 18: Verify capability through simulated working conditions
Ask if there is a simulation working condition test bench for crusher parts available. For the hammerhead, it is required to provide a life test report of its impact on basalt at an actual linear speed (such as 35m/s) on the test bench, verifying that the number of impacts reaches 120% of the design value. Verify the dynamic balance accuracy of the test bench (ISO 1940 G2.5 grade) and the data acquisition frequency (≥10kHz) to ensure that the test conditions can be reproduced.
Core Competence Seven: Technical Support and Continuous Improvement Mechanism
Checkpoint 19: Response Architecture for on-site technical support
Require the supplier to provide the qualification matrix of the technical support engineer (mechanical engineer title, failure analysis training certificate), and confirm whether they have set up permanent service points in customer-dense areas. Verify the service records of the past year and calculate the average response time and the one-time problem resolution rate. High-quality suppliers should commit to arriving at major mining areas within 24 hours and providing failure analysis reports within 72 hours.
Checkpoint 20: The conversion rate of continuously improved projects
Review the supplier’s annual continuous improvement plan to verify whether it has included the problems of crusher parts reported by customers in the improvement project pool. It is required to provide complete PDCA cycle records of at least three improvement cases, including problem definition, root cause analysis (using fishbone diagram or 5Why method), implementation of improvement measures and effect verification (cost reduction or life expectancy improvement data). Verify whether the improvement results have been solidified into FMEA or control plan updates to prevent the recurrence of problems.
The essence of evaluating a supplier of crusher parts is to verify its ability to transform materials science, precision manufacturing, and quality systems into repeatable, traceable, and verifiable processes. Procurement decisions should be based on on-site verification and data review of the above-mentioned checkpoints, rather than relying on oral commitments or static certificates. Although systematic assessment is time-consuming, it can effectively avoid the losses of tens of millions of production halts caused by the early failure of parts.
Post time: Nov-12-2025