Manufacturing Process and Unit

Production

The back bone of any manufacturing organization is the production process. Success lies in the careful synchronization of every production process. Which we achieve through carefully designed production process chart. Its implementation and the constant supervision by senior engineers, in the company round the clock, which minimizes manufacturing defects and production loss.

To achieve almost zero defect is a challenge to any manufacturer, but we love such challenge, our human resource is trained and convinced that the production process failure is not monetary loss but the loss of individual credibility. We at "DCM" check material, machinery and instruments before the commencement of work to eliminate any failure during the process, to help us achieve best results we have in house metallurgical lab and standard room to check every operation during manufacturing, steel bar are checked at different stages at regural interval and randomly, from steel bar, forging, annealing, turning, heat treatment, grinding, assembly to final packing. All process are done in perfect harmony with utmost care with most modern machinery and instruments to make best quality of bearings. It is this ability and passion, which make us different from the rest of manufacturers.

Machinery

We have state of the art machinery to carry out every manufacturing operation

1. Forging - electric heating furnace - volume 550kgs/hrs.
2. Annealing - electric annealing furnace - 3 ton capacity.
3. Turning - ACE Designer, JYOTI CNC - Junior jobber JR machines.
4. Heat Treatment - salt bath Furnace - 3 ton capacity.
5. Grinding - Surface Grinding Machine - Micromatic.
6. Vertical Grinding Machines - Cincinnati
7. PLC External Grinding Machines - Cincinnati
8. CNC Internal Grinding Machines 2 Axis - Indian
9. PLC Liff Grinding Machines - Indian
10. Honning Machine - Both side super finishing with one Ref. Only
11. Laser Marking Machine
12. Power Press Machine
13. Automatic washing Machine with Automization and air controller.

Infrastructure

We have a large industrial infrastructure build-up in one of the biggest and best veraval - sharper industrial zone in the heart of Rajkot. We have 30000 sq. feet built up area of premises for manufacturing facility and total land area of 3500 sq. meter.

Our industrial buildings are built with cement & concrete beam, column, floor reinforcement with cement & concrete to eliminate vibration during manufacturing process to achieve better accuracy.

All the raw material, under production product and finished product are kept in specially built storage to avoid atmospheric effects.

Quality Control

Quality Control is essential for the assurance of best quality products. Quality control is the key at a "DCM" and we have a dedicated team of quality inspectors engaged in constant supervision with checking and testing at different stages of manufacturing to ensure perfect size, grade and finish to achieve best Quality.

Raw Material Checking

Each and every material brought in to factory premises for bearing manufacturing is checked for steel grade. Microstructure dimensionally structure and packing material as per specification.

Quality Audit

Our team of quality experts checks balls for different factors ranging from surface roughness, roundness, size variation, hardness and noise level testing, prior to approve for final packing and dispatch to customers.

Documentation And Testing Measures

We take documentation and testing measures equally seriously. We have most modern standard room with latest "MITUTOYO" to check roughness and roundness testing and OLYMPUS Microscope for checking material micro-structure. To control in process quality, online electronic as well as mechanical comparators are used for better product quality.

Metullurgical Microscope is used for checking microscope of bearing components as per standard Mitutoyo make surftest SV - 2100 used for checking roughness and we can make choice of data analysis by computers. Easy operation, high accuracy analysis of surface roughness and evaluation of surface roughness using up to 43 parameters complying with international standards such as ISO 1997 and JIS 2001.

Mitutoyo make Contracer CV - 2000 measuring system used for measuring dimension and verifying co-ordinates and for checking radius, deep groove, degree and taper of each and every component.

Mitutoyo make Roundtest RA - 1600 is used for the measurement of roundness, straightness, cylindricity, concentricity, coaxiality, squareness and runout of bearing components, which ensure about the excellent running accuracy with long running life of bearing.