Our core competence is assembly of products, and we carry out a large range of operations including soldering, brazing, riveting, calibration, sealing, marking, coil winding, etc. All these operations are carried out under process conditions strictly controlled as per control plan. There is a lot of emphasis on poka yoke or foolproofing, even though we have a highly trained workforce with decades of experience who are really the backbone of our product quality.
There is an appropriate amount of automation in the assembly processes, starting from robotic pointer fitment, auto feed screw drivers, temperature controlled soldering stations, torque controlled tightening, etc.
The operations are vertically integrated partially, with an inhouse press shop, machine shop, dial printing shop, paint shop, anti fog coating shop and injection moulding shop. These are supported by an inhouse tool room, and an advanced manufacturing cell, which manages setting up of new assembly lines, upgrading manufacturing technology, automations and maintenance of the plant.
Quality and cost are built into a product right at the design stage, and so we pay a lot of attention to design and pre-launch activities. We have experienced and qualified designers for mechanical, electronic hardware design and for embedded software architecture. The first step of the process is to capture customer requirements accurately, and we bring our decades of domain knowledge into play by asking questions about the unstated requirements too, and including them in the SOR. The designing activities are preceded by a through DFMEA, and supplemented by strong reviews. A CFT approach is used to ensure that manufacturing process requirements are taken into account, including those at supplier end. Key suppliers are involved very early into the design process. The latest design tools including Creo, Altium etc are used extensively. APQP methodology is followed rigorously to ensure that the majority of the problems are documented and resolved prior to launch.
Our philosophy for building quality into the product is, do it right the first time. We realise that it is important to have strong processes at all stages including at our suppliers end, and we aim to prevent defects rather than detect them. Nevertheless, we do realise that strong testing is required at different stages, right from design validation testing prior to launch. We have a fully equipped laboratory inhouse for conducting environmental and fatigue tests inhouse, and have tie ups with outside labs for EMC testing. Our incoming quality cell is well equipped to test important dimensional and metallurgical parameters, and our key suppliers have the required testings in place too, an example being the AOI machines at our circuit board suppliers. Extensive in- product and in -process testings are conducted during our assembly process as well, and 100% final inspection is conducted on most of our products. For the newer product lines, this testing is automated using vision inspection rigs.
Inspite of all this, things go wrong from time to time in a manufacturing set up, and so we have trained engineers in all departments with strong problem solving skills, and very importantly very strong product and process knowledge. The aim is to analyse problems in depth and reach the root cause so that the right corrective actions can be taken. 8D methodology is used to track the solutions and to capture the knowledge gained.