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Raw Material:
Raw
material is procured by our Material management department as indicated in our
monthly production plan. All the raw materials are procured from approved
suppliers/manufacturers only. The major suppliers of raw material include M/S
Steel Authority of India Ltd., Upper India
Steel, Modern Steel, Vardhman Special Steels Ltd., Vishavkarma Steel, Mukand
Steel, Ludhiana etc. All these manufacturers
produce M.S. and Alloy Steel Flats, Rounds, Squares and Hexagon sections under
strict quality norms as per relevant ISS/BSS/DIN/ASTM specifications and are
well equipped with in-plant material test facilities for Chemical and
Mechanical properties. The major lots are accompanied with manufacturer's test
certificate bearing Heat No. and colour code as per relevant
specifications.
These raw materials are again tested for Chemical properties in our own test
lab. to verify the values of various elements given by the manufacturer of
Iron and Steel. On verification of Chemical properties, an identification (Q.
No.) is marked on the lot of material tested and a document is generated for
the same which is transferred to 'Job Route Card'(Annex. A). A stock register
is maintained for the receipt and issue of raw materials for various items as
per requirements indicated in the Job Route card as per specimen.
Different grades of raw material are stacked at appropriate places earmarked
for the purpose to avoid any mix up. Proper colour codification is maintained
at all stages.
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The
manufacturing process of Bolts/screws consists of blank cutting from round
bars, forging/upsetting head by cold/hot process depending on size,
trimming, facing, centre less grinding of shank, thread rolling,
annealing, hardening, tempering, cleaning, plating, dispatch.
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The
manufacturing process of Nuts consists of blank cutting from round bars on
Auto/ Semi auto Nut cutting machines or hot / cold forgings depending on
size, chamfering, tapping, annealing, hardening, tempering, cleaning,
plating, dispatch.
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The
manufacturing process of Studs consists of blank cutting from round bars,
facing, chamfering, centreless grinding of shank, thread rolling,
annealing, hardening, tempering, cleaning, plating, dispatch.
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The
manufacturing process of Pins consists of blank cutting from round bars,
forging/upsetting head by cold/hot process depending on size, trimming,
turning to size, milling/drilling, case carburising, hardening, tempering,
centreless grinding of shank, thread rolling, if any, plating, dispatch.
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The
manufacturing process of Washers consists of blank cutting from round bars
on automats, facing, chamfering, hardening, tempering, cleaning, plating, dispatch.
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The
manufacturing process of Nuts by Cold forming process consists of feeding
the rounds in coils in the imported Nut formers which automatically forms
the shape of a Hex/Flanged Nut/Weld Nut after passing through six inbuilt
stations. These Nuts are then tapped in the Automatic Nut tapping
Machines.
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A
specific Quality policy exists in out unit. It is clearly defined to check the
products at various stages of manufacture and at the end of all operations. It
is ensured both by the workmen and quality staff on duty for this purpose. To
achieve this aim and make a fool proof system, a Job Route Card (Annexure 'A')
on the. basis of Quality Plan (Annexure 'C') is introduced while launching the
production of each item and stage inspection is carried out during each
operation/after each operation on sampling basis as per Sampling Plan for
Threaded Fasteners, I.S. 2614 by the concerned workmen and counter checked by
QC staff.
During
the manufacture of items, if any dimensions is not confirming to drawing, a
Non conformity Report (NCR) is prepared and corrective action is taken then and
there. Since ours is a mass production producing unit, sizes are thoroughly
checked during the setting of the job as such negligible NCR's are raised.
Quality control staff has the authority to stop the operation if any deviation
in dimensions/process is observed at any stage of manufacture. Work is allowed
to proceed further only after the necessary corrective action is taken.
The
movement of material during various processes is strictly restricted in
"BINS" specially employed for this purpose along with Job Route Card
to avoid any mix up of various products and strictest quality control is
maintained for all dimensions/processes. At the end of all the processes,
final inspection is done by the Quality staff as per Sampling Plan for
threaded fasteners I.S. 2614 and an Observation sheet is generated as per
specimen enclosed as Annexure 'D.'
Thus
the following documents are maintained for each item.
01.
Job Route Card duly certified by QC staff.
02.
Observation sheet duly certified by QC staff.
03.
Test certificate for Chemical/Mechanical Properties as per requirements of
Customers duly certified by QC staff. The copy of the test certificate is sent
to the Customer along with dispatch documents.
All
the above documents are maintained by QC staff which are easily retrievable.
These documents are normally retained for a period of three years.
After
the material is cleared for dispatch by QC staff, the same is handed over to
our Dispatch section who .pack the material in standard Card boxes/cartoons or
as per specific requirements of the customers after applying Anti corrosive
oil. These card boxes/cartoons are then dispatched in Wooden boxes. Each box
is identified with Size, grade and quantity of product. The records of receipt
and issue of. finished goods is kept by the dispatch section. The stock items
are properly identified for Size, grade and quantity and a proper record is
maintained Rack/Box wise. The Stock is periodically reviewed for its
correctness and quality.
Thus a total quality environment exists in our unit which has led to a wide
acceptability of our products among various Govt. Organisation/Public Sector
Organisations/Private Large Scale Industries/our Authorised and registered
dealers allover the country and International Market through Export Houses. We
are proud of our achievements and total Quality Product.
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