Manufacturing Process

The plants follow lean manufacturing systems and cellular manufacturing. The layout has been designed through value stream mapping and with an aim to achieve the best floor space utilization. The company has worked extensively with the Kaizen Institute since 2001 to maximize production efficiency and has deployed tools such as Single Minute exchange of Dies (SMED), Just in Time (JIT), Error Proofing (Poka Yoke) and Statistical Controls over a number of years.

In order to generate maximum value and optimize costs, the plant carries out a variety of operations in house.

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Processes

The company carries out a variety of processes which include:

Plant 1   Grinding.   Resistance welding: Projection and seam welding, Mig / Mag welding.   Automated Hard chrome Plating with SCADA system.   Conveyorized powder coating with pre-treatment.   Burnishing and Superfinishing.   Assembly of shock absorbers, dampers & gas springs.

Plant 2   Stamping.   Robotic welding.   Automated welding.   Painting.   Assembly.

The manufacturing facilities include various special purpose machines in addition to the above.

Quality

Duroshox has been accredited with ISO 9001:2000 & ISO/TS-16949:2002 certification and has a goal to achieve “0” PPM (parts per million) of product failure.

CMM   Weld Analysis Lab as per ASTM standards   Profile Projector   UTM   Salt Spray   Damping testers

Endurance Testers.   Vibration analysis for industrial applications   Seat Slide endurance and fatigue test equipment   Contamination test equipment (Millipore testing)