Manufacturing Facilities
USHA has an excellent manufacturing facility with over 250 CNC machines such as the latest state-of-the-art CNC controlled turning centers, machining centers, very high precision internal and external grinders and super-finishing machines. USHA also has a full-fledged heat-treatment facility including sealed quench furnace, vacuum hardening furnace and sub-zero treatment. This is supported by extensive inspection and testing facilities including a modern standards room and metallurgical laboratory.
USHA’s core strengths are:
- cost-effective manufacturing facility
- highly skilled workforce
- precision manufacturing and testing equipment
- heat-treatment facility and metallurgical laboratory
- tool division and standards room
- structured and streamlined manufacturing systems based on Japanese manufacturing practices like kaizen, kanban, jidoka, etc.
Machinery
USHA has an extensive range of modern manufacturing equipment. In particular, USHA has the following machinery and manufacturing facilities:
- CNC turning centers – Citizen, Haas, DMG Mori, Mori Seiki, Keiyo Seiki, Mazak, etc.
- Machining centers – Brother, Haas, TAL, Hitachi, Fanuc, Bridgeport, etc.
- CNC cylindrical grinders – Studer, Landis, Kondo, TOS, Micromatic, etc.
- Centerless grinders – Cincinnati, Herminghausen, Lidkoping, Paragon, Palmary, etc.
- Precision surface lap grinders – Ichikawa, Peter Wolters, Jones & Shipman, etc.
- High precision internal grinders – UVA, Tripet, Overbeck, etc.
Special Machinery
USHA also has special and unconventional manufacturing facilities such as abrasive flow machining (AFM) and electro-chemical machining (ECM).
The manufacturing facilities available at USHA are capable of generating extremely close dimensional and geometrical accuracies. Several of USHA’s products are manufactured to tolerances of few microns with very high process capability levels.
Heat Treatment
USHA has excellent skills in heat treatment of all kinds of alloy steels. USHA has a full-fledged heat-treatment facility comprising of the following:
- Vacuum hardening furnace – Ipsen
- Sealed quench furnace – Ipsen
- Sub-zero treatment (Deep freezers) – Cincinnati Sub Zero (CSZ)
The heat treatment facility is accompanied by a well-equipped metallurgical laboratory with the following facilities:
- Brinell, Vickers & Rockwell hardness tester
- Micro-hardness tester
- Computer aided microstructure analysis
- High resolution metallurgical microscope for microstructure
- Magna flux crack detector
USHA is associated with an accredited source for testing of the chemical composition of raw materials.
Tool Division
USHA also has a dedicated Tool Division where it has precision machinery for manufacture of jigs, fixtures, tools and gauges. The Tool Division has excellent skills in the manufacture of:
- Press tools
- Die-casting tools
- Precision fixtures and gauges
- Development of prototypes
USHA has been manufacturing toolings for prestigious customers such as Honda, Videocon, Voltas, Tecumseh, Godrej, Lucas TVS, BHEL and many others.
The machining facilities at the Tool Division include:
- Conventional turning, drilling, milling, shaping, etc.
- CNC 5-axis machining centers
- Precision jig boring and jig grinding
- Wire-cut
- Electro-discharge machining (EDM) / Spark erosion
- High precision cylindrical (internal and external) grinding
Inspection & Testing Facilities
USHA has an extensive system for online inspection of parts during manufacturing. The quality control system is thoroughly compliant with the requirements of quality standards.
Quality Control & Teamwork
USHA has an excellent system of Quality Control that encompasses all the requirements of gage calibration, measurement systems analysis, statistical process control and product quality planning. The system of gage calibration is linked to the National Physical Laboratory.
There also is a well-established system for controlling the manufacturing processes online based on the operator control charts.
USHA has highly skilled and experienced workforce whose skills are continually upgraded through training. Workmen at USHA are committed towards improving the quality of the products as well as improving the working environment – this is achieved through Quality Circles wherein groups of workmen voluntarily come together to discuss quality related issues for improvement and progress.
Standards Room
USHA also has a full-fledged Standards Room which is capable of inspecting the most stringent and precision components. It also has the most modern testing and inspection equipment which is partially listed below:
- Form geometry (roundness / cylindricity / straightness / flatness) tester
- Surface roughness tester
- Coordinate Measuring Machine (CMM)
- Contour checking instrument
- 2-dimensional coordinate measuring equipment
- Tool maker’s microscopes
Finished Product Audit
In order to ensure customer satisfaction and delight USHA also has a well-established system for checking the products for fitment, performance and functional parameters before dispatch. This is done on a random sampling basis for every batch of product, before dispatch.
Further, the data collected from the in-process manufacturing operations through operator control charts is analyzed through trend charts and statistical analytical tools.
Precision Components Division
Usha Precision Components Division, with a wide array of manufacturing and inspection facilities and with over 25 years of experience in the manufacture of precision diesel fuel injection equipment has now embarked upon the manufacture of precision automotive components.
Usha has dedicated manufacturing and testing lines for specific customers called CEL – Customer Exclusive Location. Usha has earmarked specific areas and installed machines and inspection & testing equipment for major customers. Usha’s commitment towards its customers is reflected in these CELs – each CEL is an extension of the customer’s manufacturing facility.
Globally renowned companies such as Stanadyne SpA, Italy, Denso Haryana Pvt. Ltd. (the Indian subsidiary of Denso, Japan), Honda Siel Power Products, Marelli, Italy and VST Tillers & Tractors, India are now turning to USHA for outsourcing of various for diesel and gasoline fuel injection equipment and precision machined parts.
Technical Capability
Usha is capable of producing parts that have sub-micron dimensional and geometric tolerances – Usha regularly makes parts that are tolerated within 0.001mm or one millionth of a meter with measuring capabilities within 100 nanometers! And these parts have near-perfect form geometries like roundness and cylindricity within fraction of microns!
Parts manufactured to such close tolerances must be super-finished to extremely fine surface finishes. Usha is normally capable of generating turned surfaces with a finish of Ra 0.50 microns and ground / honed / lapped / super-finished surfaces with a finish of Ra 0.05 microns.
Usha manufactures parts in various heat-treatable alloy steels including through hardening ball bearing steels, high-speed steels, stainless steels, case-hardening steels, nitriding steels and many more. All these steels are procured from the most reputed domestic and international steel mills with necessary test certificates and subsequently tested by Usha.
The core strength of Usha comes from an excellent heat-treatment facility for steels supported by a metallurgical laboratory which is capable of producing the most consistent quality of heat-treated parts.
Usha’s technical capabilities are reflected in its extensive manufacturing, heat-treatment, inspection and product testing facilities. In the following pages you will discover how Usha with its rich experience and technical expertise in precision component manufacturing
Made at USHA
Usha is dedicated to offering all its customers the best product quality at the lowest prices with on-time delivery and a committed after-sales support. Usha could establish dedicated CELs for its new customers for manufacturing their products.
USHA with its extensive manufacturing, heat-treatment, inspection, testing and assembly facilities is the preferred destination for high precision automotive components.
