Company Presentation

NO. 66 JALAN BJ 6, TAMAN PERINDUSTRIAN

BELMAS JOHAN
48200 RAWANG SELANGOR DARUL EHSAN
MALAYSIA EMAIL: service@wiresawservice.com
Contents
Company Profile
Mission and Vision
Production Capacity and Process Flow
QC Process
Bearing Taper Repair
Management Policy
Machinery and Equipment
Service and Support
Company Profile
Uji Nescaya Sdn. Bhd. (UN) was
established in 2004 by a core
management team with more than 15
years of experience in the precision
casting of (P.U) polyurethane coated
rollers.

Our primary focus is in the manufacture

and resurfacing of high quality precision
cast polyurethane guide roller
components. These industrial duty Established : 2004
rollers are essential in the precision Capital : RM 1 million/350,000 USD
cutting of semiconductor wafers used in Employees : 7
the manufacture of photovoltaic cells
Managing Director : Tharmarajah Ramasamy
and microprocessor chips.

The factory location:

Our proprietary methods and processes
No. 66, Jalan BJ 6,
offer companies within these industries
an opportunity to lower costs Taman Perindustrian Belmas Johan,
associated with PU roller maintenance 48200, Rawang,
and replacement. Selangor, Malaysia
Mission and Vision

Our Mission and Vision:

To provide superior production
quality, capacity and prompt
turnaround time to our growing
customer base.
Through continually monitoring
and improving our performance
against set and targeted
objectives.
By striving to increase the
durability and the prevention of
failure through completely This we accomplish by applying the knowledge which we
eliminating defects and thus have acquired over the years to enhance our products,
increasing customer satisfaction. processes and services.
Production capacity
and Process Flow
NEW MAIN ROLLER MANUFACTURE
AND PROCESSING TIME:

Stage 1

UN’s proprietary methods and processes

result in a durable and bubble free PU
coating. We use quality two component
PU which is very robust resulting in a
longer life span and overall durability.
This benefits our customers in numerous
ways that reduce costs and waste as well
as it provides a means of increasing the
Above
precision of the cutting process.
Freshly cast PU coated roller
Production capacity and
Process Flow
Stage 2

Shaving and surfacing of the

freshly coated PU roller
assembly.
Production capacity and
Process Flow
Stage 3

At this stage the PU coated rollers

are ready to be calibrated for groove
and pitch cutting.

Shaved and newly surfaced roller for ready

for CNC process
Production capacity and
Process Flow

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

Ready for
Work order Shaving
Apply New Shaving and Groove Pitch shipment
Received from and QC / Packaging
P.U Coating surfacing Cutting and delivery
Customer surfacing
to customer
5 days 2 day
 MAIN ROLLER NEW P.U PROCESS FLOW

Work order Received from → Wipe bearing & P.U → Inspect rollers for design specs
customer bearing Diameter & P.U
condition
↓

Inspection of the P.U physical Apply the new P.U coating

← ← Shave to bearing size
appearance and design process
specification

↓
Check diameter and No Good Reject
Shave to required diameter & → inspect roller for particles →
polishing of the bearing & bubbles Good
Send to CNC – final shaving and
surfacing

Quality Control (QC) ← Groove Pitch Cutting ← Final inspection of hardness /

diameter & P.U condition

↓
→ →
Packaging Store Shipment and Delivery
 REGROOVE MAIN ROLLER PROCESSING TIME
Total : 1 working day ( Subject to max. 3 sets per day )

Work Received Ready for

Shaving and Groove Pitch
from QC / Packaging Customer
Surfacing Cutting
Customer Delivery
1 day

By measuring on the contour graph we read the angle and grove

pitch to an accuracy of .05 micro tolerance this provides our
customers with the additional assurance of accuracy and
tolerance.
MAIN ROLLER
REGROOVE PROCESS
FLOW
1) Receive roller
from customer
2) Clean
bearing & PU
3) The rollers are
transported to the
shaving and
surfacing area
by scissor lift
4) In the shaving
and surfacing area,
the condition of
roller will be
recorded to
include the roller
number, diameter,
it’s bearing
specification and
PU condition.
5) Shave and
surface to the
specified diameter
& polishing of the
bearing itself
6) Verify it’s
diameter and
inspect for any
foreign particles
and/or bubbles
7) CNC – Final
Shaving and
Surfacing
8) Check
hardness /
diameter and
the PU condition
9) Unload the
roller from CNC
machine
10) Each roller will
go through a
quality control
inspection to
verify pitch depth,
groove spacing,
diameter, and
hardness. This
vital information is
printed and sent
along with the
work to the
customer for their
records and
review.
11) Packing
Crating for shipping and
delivery to customer
GUIDE ROLLER
PROCESSING TIME

Note: Production and processing based

upon two CNC machines working 16
hours per day
Production capacity : 150 pieces per
day

2nd Process
Received Material from 1st Process
OD & Side cutting + QC / Packaging Ready for Delivery
Customer ID & Side cutting
Pitch

1 day 1 day
GUIDE ROLLER PROCESS
FLOW

Received from customer → Physical Inspection → Storage

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

CNC 2nd side, OD → Check diameter, thickness, → Quality Control (QC)

Shaving & grooving ID, OD, surface, particle, Final and complete
bubble, groove & hardness checking
Quality Control
Process

1) Using a lift to unload

the roller from CNC
machine
QC Process continued

2) The roller is
transported to the QC
room for inspection.
QC Process
continued
3) Contour graph machine
is calibrated for roller
inspection
QC Process
continued

4) Front point
inspection
QC Process
continued

5) Centre point
inspection
QC Control
continued

6) Rear point
inspection
QC Process
continued
t
7) All the data
accumulated from the
rollers inspection is
displayed to the
computer and printed
for inclusion with the
work when it is
returned to the
customer.
QC Process
continued

8) Ensure all the

roller specifications
are as per
customer’s
requirements.
QC Process
continued

9) Report from the

roller inspection is
print out and
attached to QC
Inspection Sheet.
Bearing Taper
Repair

Here jigs are used to

determine bearing
condition.
Bearing Taper
Repair

Checking of the bearing

taper
Bearing Taper
Repair

Main roller await

bearing repairs
Bearing Taper
Repair continued
As a result of the demands in the
manufacturing process and to over
use, often the main roller bearing
taper loses its design specification.
This negatively impacts the
operation of the main roller and its
function within the machine.
Replacement of main roller can be
very costly and the time factor is
also a major concern.

At Uji Nescaya, we have the

experience and expertise in bearing
taper righting and repairing. We
insure that all customer
specification are achieved and
adhered to including the bearing
gap, balance, taper hardness and
most significantly we ensure that
there is no shaking and tilting of the
main roller.
Towards ISO 9001
Quality is the basic requirement for the
satisfaction of our customer and the resulting
competitiveness and economic success of
UN. Under going for ISO certification has
permitted us to improve internal processes,
provide better training to our staff and
establish excellent relations with
vendors/customer. Going forward it will help
us to focus on our customer’s needs through
continual improvement and the setting of
quality objectives.

To achieve this goal, we have set the

following policy as our management
principles:

We recognize that our services have value

only if they contribute to the development of
our customers’ business.
We endeavor to detect the latent needs of
our customers in order to ascertain
accurately their exact requirements.
We work proactively to improve the quality
of our services in order to offer our
customers the high level of quality that they
demand.
Our commitment to our
customers is back up by a full
guarantee.
Finally we work directly with our customers to
support their demanding production
requirements.
We understand the importance of responding
quickly to our customer inquiries and we also
understand that providing a quality product in a
timely fashion is only part of what our customers
require. This is why we work directly with our
customers to throughout the manufacturing and
repair process as may be necessary.
We look forward to
serving you!
Uji Nescaya has spared no effort or expense in
providing highly efficient service of indisputable
quality because total customer satisfaction is vital
to the success of our company.

This service is supported by our dedicated and

professional staff. Every member of the Uji
Nescaya team has undergone intensive in-house
and on the job training.