Sabsons Fastners filaments meet the highest international standards of excellence. Each and every filament from the Sabsons Fastners plant is individually inspected for quality supported by the most sophisticated and exhaustive statistical quality control systems from the raw material stage to the stage of manufacture – using the finest equipment available. A binocular microscope magnifies filaments to 200 times their size to detect any irregularities or defects that might escape a micro projector unit. An in-house, pilot lamp making plant constantly monitors the performance of the filament by producing lamps of all types which are subjected to the most rigorous test possible. And finally, there is the life test where filaments are tested under simulated conditions of actual performance. The result of all these factors is a filament of very high standard.
This is further aided by Sabsons Fastners in-house developed sophisticated Computer based design which co-relates customer feedbacks to design ensuring customer specific product development.Further, 100% machines are equipped with electric control system to ensure zero-defect no. of turns.
The quality assurance system has three segments :
Approval of design
Control at wire drawing
Control at coil manufacturing
Performance of a manufacturing system depends upon 4.M factors, namely Man, Machine, Method and Material Man – Employees of Sabsons Fastners are highly educated (all are graduates, the best in industry) and suitably trained.
Machine – All the machines were purchased from sources known to be the best in the industry e.g. Wire drawing M/C from OY AIRAM of FINLAND Coiling Machines from FALMA, SWITZERLAND and WAFIOS, GERMANY.
Method – Sabsons Fastners adopted technology of AIRAM and FALMA, which has been upgraded suitably by Sabsons Fastners Engineers.
Material – It is Sabsons Fastnerss policy not to compromise on raw material.
GE, (USA), OSRAM(GERMANY), are our usual suppliers
Filament manufacturing involves a series of processes, each of which need very delicate control of product as well as process parameters. The problem is more acute because, apart from the physical dimensions and the so called destructive test, other parameters are checked on the basis of lamp performance on which the filament manufacturers have no control. It is a well known fact lamp parameters, like (a) filling gas composition, (b) filling gas pressure and to some extent (c) the mount geometry – vary widely from customer to customer, and each of those has significant effect on lamp performance. However, Sabsons Fastners acknowledges the importance of customers specification – and hence tries to design filament – specific to a customer.Sabsons Fastners rely on customerss feedback – and modify the coil data – continuously to suit the requirement.
Once the design gets customerss approval – the coil data is stored in our CAD system to ensure consistently similar product.
CONTROL AT WIRE DRAWING:
Drawing of Tungsten and Molybdenum wire – down to sizes of around 20 micron needs high degree of technical monitoring of all parameter, namely
% RA – per die
Sabsons Fastnerss technical team constanty monitor the parameterss to ensure
High resolution microscopes, electronic balances of high sensitivity (0.01mg), infra-red radiation pyrometer, sophisticated T.S. testing machine having direct recording of % elongation etc. are some of the important equipments. The detail of check-points is given in the quality plan.
CONTROL AT COILING:
Every lot is produced with the aid of CAD – specific to a particular customer.
100% primary coil spools are checked to detect pitch uniformity, by (a) using microscope and (b) mg/200mm coil weight.
At secondary coiling, we have continuous TURN monitoring system and we work on ZERO tolerance for NUMBER OF TURNS
Coil annealing is done under hydrogen environment and controlled temperature. Radiation pyrometers are used to measure temperature accurately.
Sabsons Fastners use closed dissolving plant – of FALMA make for mandrel dissolving which ensures uniform etching.
Sabsons Fastners employs 100% visual inspection prior to packing to ensure quality of filament.
All quality parameters are checked twice, firstly prior to visual inspection and secondly prior to delivery
With all these efforts and with our commitment to meet the customers requirement – Sabsons Fastners can assure quality products consistently.
PROCESS CONTROL: An integral part of Quality Assurance