uji nescaya company process profile and presentation

8/14/2019 Uji Nescaya Company Process Profile and Presentation

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NO. 66 JALAN BJ 6, TAMAN PERINDUSTRIAN BJ48200 RAWANG SELANGOR DARUL EHSAN

EMAIL: [email protected] number: 6-012-444-3593
mailto:[email protected]:[email protected]


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Contents Contents Company ProfileMission and VisionProduction Capacity and ProcessFlowQC ProcessBearing Taper Repair

Management PolicyMachinery and EquipmentService and Support


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Company ProfileCompany ProfileUji Nescaya Sdn Bhd (UN) was establishedin 2004 by a core management team withmore than 15 years of experience in theprecision casting of (P.U) polyurethanecoated rollers.

Our primary focus is in the manufactureand resurfacing of high quality precisioncast polyurethane guide roller components.These industrial duty rollers are essentialin the precision cutting of semiconductorwafers used in the manufacture ofphotovoltaic cells and microprocessor

chips.Our proprietary methods and processesoffer companies within these industries anopportunity to lower costs associated withPU roller maintenance and replacement.

Established : 2004Capital : RM 1 million/350,000 USDEmployees : 7Managing Director : TharmarajahRamasamy

The factory location:No. 66, Jalan BJ 6,Taman Perindustrian Belmas Johan,48200, Rawang,Selangor, MALAYSIA.


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Mission and Mission and VisionVisionOur Mission and Vision:

To provide superiorproduction quality, capacityand prompt turnaround timeto our growing customer base.Through continuallymonitoring and improving our

performance against set andtargeted objectives.By striving to increase thedurability and the preventionof failure through completelyeliminating defects and thusincreasing customersatisfaction.This we accomplish byapplying the knowledge whichwe have acquired over theyears to enhance our products,processes and services.


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Production capacity Production capacity and Process Flow and Process Flow NEW MAIN ROLLER

MANUFACTURE ANDPROCESSING TIME:

Stage 1

AboveFreshly cast PU coated roller

UNs proprietary methods andprocesses result in a durable andbubble free PU coating. We use qualitytwo component PU which is veryrobust resulting in a longer life span

and overall durability.This benefits our customers innumerous ways that reduce costs andwaste as well as it provides a means ofincreasing the precision of the cuttingprocess.


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Production capacity Production capacity and Process Flow and Process Flow

Stage 2

Shaving and surfacing of thefreshly coated PU roller

assembly.


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Stage 3

Shaved and newly surfaced roller for

ready for CNC process

At this stage the PU coated rollersare ready to be calibrated forgroove and pitch cutting.


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Work order Received from

Customer

Shavingand

surfacing

Apply NewP.U Coating

Shaving andsurfacing

Groove PitchCutting

QC / Packaging

Ready for shipment

and deliveryto customer

5 days 2 day

Total: 7 working days (Subject to max. 3 sets per delivery)


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MAIN ROLLER NEW P.U PROCESS FLOW MAIN ROLLER NEW P.U PROCESS FLOW

Work order Received fromcustomer

Wipe bearing & P.U Inspect rollers for designspecs bearing Diameter & P.U

condition

Inspection of the P.U physicalappearance and design

specification

Apply the new P.U

coating process Shave to bearing size

Shave to required diameter & polishing of the bearing

Check diameter and

inspect roller for particles & bubbles

No Good

Good

Reject

Send to CNC final shavingand surfacing

Quality Control (QC) Groove Pitch Cutting Final inspection of hardness /diameter & P.U condition

Packaging Store Shipment and Delivery


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Work Receivedfrom

Customer

Shavingand

Surfacing

Groove Pitch

CuttingQC / Packaging

Ready for Customer Delivery

1 day

REGROOVE MAIN ROLLER PROCESSING TIME Total : 1 working day ( Subject to max. 3 sets per day )

By measuring on the contour graph we read the angle andgrove pitch to an accuracy of .05 micro tolerance thisprovides our customers with the additional assurance of

accuracy and tolerance.


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MAIN ROLLER MAIN ROLLER REGROOVE PROCESS REGROOVE PROCESS FLOW FLOW


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1) Receive roller 1) Receive roller from customer from customer


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2) Clean2) Cleanbearing & PU bearing & PU


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3) The rollers 3) The rollers

are transported are transported to the shaving to the shaving and surfacing and surfacing area area

by scissor lift by scissor lift


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4) In the4) In theshaving and shaving and

surfacing area,surfacing area,the condition of the condition of roller will beroller will berecorded to recorded to include theinclude theroller number,roller number,diameter, its diameter, its bearing bearing specificationspecificationand PU and PU condition.condition.


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5) Shave and 5) Shave and

surface to thesurface to thespecified specified diameter & diameter & polishing of thepolishing of thebearing itself bearing itself


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6) Verify its 6) Verify its

diameter and diameter and inspect for any inspect for any foreignforeignparticles and/or particles and/or

bubbles bubbles


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7) CNC 7) CNC Final Final Shaving and Shaving and Surfacing Surfacing


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8) Check 8) Check

hardness / hardness / diameter and diameter and the PU the PU conditioncondition


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9) Unload the9) Unload theroller from CNC roller from CNC machinemachine


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10) Each roller 10) Each roller will go through a will go through a

quality control quality control inspection to inspection to verify pitchverify pitchdepth, groovedepth, groovespacing,spacing,

diameter, and diameter, and hardness. This hardness. This vital informationvital informationis printed and is printed and sent along withsent along withthe work to thethe work to thecustomer for customer for their records and their records and review.review.


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11) Packing 11) Packing


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Crating for shipping and Crating for shipping and delivery to customer delivery to customer


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GUIDE ROLLER GUIDE ROLLER PROCESSING TIME PROCESSING TIME

Note: Production and processing basedupon two CNC machines working 16hours per dayProduction capacity : 150 pieces per day

Received Materialfrom Customer

1st ProcessID & Side cutting

2nd ProcessOD & Side cutting +

Pitch

QC /Packaging

Ready for Delivery

1 day 1 day


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GUIDE ROLLER GUIDE ROLLER PROCESS FLOW PROCESS FLOW

Received from customer Physical Inspection Storage

CNC 1 st side machining I.D. & side shaving and surfacingCheck the I.D by using guide roller bearing

CNC 2 nd side, ODShaving & grooving

Check diameter, thickness,ID, OD, surface, particle,

bubble, groove & hardness

Quality Control(QC)

Final and completechecking


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Quality Control Quality Control Process Process

1) Using a lift tounload the roller fromCNC machine


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QC Process QC Process continued continued

2) The roller istransported to theQC room forinspection.


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QC Process QC Process

continued continued 3) Contour graphmachine is calibratedfor roller inspection


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4) Front pointinspection


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5) Centre pointinspection


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QC Control QC Control continued continued

6) Rear pointinspection


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7) All the dataaccumulated fromthe rollers inspectionis displayed to thecomputer and

printed for inclusionwith the work whenit is returned to thecustomer.


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8) Ensure all therollerspecifications areas per customersrequirements.


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9) Report from theroller inspectionis print out andattached to QCInspection Sheet.


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Bearing Taper Bearing Taper Repair Repair

Here jigs are used todetermine bearingcondition.


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Checking of thebearing taper


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Main roller awaitbearing repairs


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Bearing Taper Bearing Taper Repair continued Repair continued As a result of the demands in themanufacturing process and toover use, often the main rollerbearing taper loses its designspecification. This negativelyimpacts the operation of themain roller and its function

within the machine.Replacement of main roller canbe very costly and the timefactor is also a major concern.

At Uji Nescaya, we have theexperience and expertise in

bearing taper righting andrepairing. We insure that allcustomer specification areachieved and adhered toincluding the bearing gap,balance, taper hardness andmost significantly we ensure

that there is no shaking andtilting of the main roller.


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Towards ISO 9001Towards ISO 9001Quality is the basic requirement for thesatisfaction of our customer and theresulting competitiveness and economicsuccess of UN. Under going for ISOcertification has permitted us to improveinternal processes, provide better trainingto our staff and establish excellentrelations with vendors/customer. Goingforward it will help us to focus on ourcustomers needs through continualimprovement and the setting of qualityobjectives.

To achieve this goal, we have set thefollowing policy as our managementprinciples:

We recognize that our services have valueonly if they contribute to thedevelopment of our customers business.We endeavor to detect the latent needs ofour customers in order to ascertainaccurately their exact requirements.We work proactively to improve thequality of our services in order to offerour customers the high level of qualitythat they demand.

Our commitment toOur commitment to


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Our commitment to Our commitment to our customers is back our customers is back up by a full guarantee.up by a full guarantee.Finally we work directly with ourcustomers to support their demanding production requirements.

We understand the importance ofresponding quickly to our customer inquiriesand we also understand that providing a

quality product in a timely fashion is onlypart of what our customers require. This iswhy we work directly with our customers tothroughout the manufacturing and repairprocess as may be necessary.

Uji Nescaya has spared no effort or expense

in providing highly efficient service ofindisputable quality because total customersatisfaction is vital to the success of ourcompany.

This service is supported by our dedicatedand professional staff. Every member of the

We look forward We look forward to serving you! to serving you!

uji nescaya company process profile and presentation

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