filaments meet the highest international standards of excellence.
Each and every filament from the WEBFIL 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 WEBFIL's 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 WEBFIL 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 – WEBFIL adopted technology
of AIRAM and FALMA, which has been upgraded suitably by WEBFIL’S
Material – It is WEBFIL’s 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, WEBFIL acknowledges the importance
of `customer’s specification’ – and hence
tries to design filament – specific to a customer. WEBFIL
rely on customers’s feedback – and modify the
coil data – continuously to suit the requirement.
Once the design gets customers’s approval – the
coil data is stored in our `CAD’ system to ensure consistently
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
- Drawing dies
- % RA – per die
- Drawing speed
- Tensile strength
WEBFIL’s technical team constanty
monitor the parameters’s to ensure
- Smooth and
- Round wire
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.
- WEBFIL use `closed dissolving plant’
– of `FALMA’ make for mandrel dissolving which
ensures uniform etching.
- WEBFIL 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
customer’s requirement – WEBFIL
can assure quality products consistently.