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Printed Circuit Boards

Hybrid Microcircuits

Multi Layer PCB ( FPGA/BGA) Assembly Fine Pitch

PCB Repairs and Maintainance

Micro Controller Based Control Card

Switching Mode Power Supplies (SMPs)

Circuit Board Design & Development

Electronics Manufacturing Services

PCB Assembly

Fine Pitch Soldering


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About Us Infrastructure

About Us

Established in 1992 at Navi Mumbai, Maharashtra, India, our business operations are led by Mr. Deepak Sawant. His valuable process approach as well as services of experienced industry professionals allows us to successfully handle the demands of Embedded designs, PCB CAD Centre for up gradation of Designs, Layouts and Fast prototype assembly. Further, we also meet the requirements of Electronic Manufacturing Services, in Circuit & Functional testing, Conformal Coating & Encapsulation and Reliability Testing.

 

Today, our capability to deliver consistent service standards is backed by experienced management and our experienced team. The strengths of our team including competent technical background & experience, consistent track record in EMS segment (Catering to wide applications) and capability to offer total solution from design, prototyping, assembly to testing also ensure the solutions offered by us are compatible with those demanded in the market. We also carry out constant thrust on employee training & skills enhancements. Our Six sigma approach towards making necessary process improvement also ensure that our team is at par with the demands of the customers.

Company Profile
Basic Information
Business Type
  • Manufacturer
  • Exporter
  • Service Provider
Ownership & Capital
Year of Establishment
1992
Ownership Type
Limited Liability/Corporation (Privately Held)
Trade & Market
Major Markets
  • Indian Subcontinent
  • East Europe
  • North Europe
  • Middle East
Team & Staff
Total Number of Employees
51 to 100 People
Company USP
Quality Measures/Testing Facilities
Yes

The Team

Deepak G. Sawant (Managing Director):
  • Post graduate in Solid State Electronics
  • Worked with Indian Institute of Science
  • Professional Experience : 27 Years 
  • Member of SMTA, IMAPS, ELCINA
    • Science Post graduate and Management Professional
    • Worked with Hoechst Research & Multinationals like Cadburys, Hindustan Unilever Limited as QA Head
    • Professional Experience : 21 Years 
    • ISO 9001:2000 Lead Auditor

The Team

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Manufacturing Unit

  • 42 employees

  • Government approved apprentice training centre

  • Managerial staff : Engineers, Electronics Post graduates with vast industry & management experience

  • Supervisors & asst. managers

  • Diploma engineers, graduates

  • Operators : ITI , NCTVT certificate holders

Manufacturing Unit

Strength & Services

  • Competent technical background & experience of the promoters.
  • Consistent track record in EMS segment catering to wide applications.
  • Total solution offering from design, prototyping, assembly to testing.
  • Constant thrust on Employee Training & skills enhancement
  • Six sigma approach towards process improvement.
    • Miniaturization of PCB assemblies
    • Conversion of through-hole ( conventional ) assemblies into SMT cards using CAD tools
    • Design & development of Hybrid Microcircuits
    • Electronic Manufacturing Services / Contract Manufacturing

Mision & Vision

Mission statement: Emerge, as a leader in Surface Mount Technology (SMT) by providing Total Solution for customized needs in Design Conversion & Manufacturing.


Vision statement: To be recognized as the most successful & low cost electronics manufacturing service provider in organized corporate sector.

  • Motivate performers to see a bigger picture and set goals with execution & end result in mind
  • Train & treat employees with respect, cultivate confidence & decision making abilities.
  • Practice Innovation,Integration & Involvement. Emphasize on Vision, not supervision.
  • Develop systems with emphasis on customer focus & continual improvement
    • Electronic Manufacturing Services

    • Contract Manufacturing ( Equipment Building )

    • Conversion of conventional assemblies in to Mix technology SMT cards

    • Design & Development of Hybrid microcircuits

    • Prototype support for Embedded design

    • Repairs, Rework & Maintenance of PCB cards


Why Us

  • Miniaturization - Higher packing density, Fine pictch component assembly, process oriented approach
  • Higher reliability – Thermal Aging ,Burn In test
  • Better performance – Checks on BOM as per ERC, DRC, Conditional Placement, Signal Integrity , EMI/EMC (SI)
  • Flexibility in adpoting engineering change overs due to lean process approach & maintenance of data & offline documentation support
  • Economics - Reduction in PCB, Components, Assembly, Repair Costing
  • High production volumes – automated process, design for manufacturablity (IPC-782) & process capability
  • Implementation of Quality Standards (IPC-A-610C)

 

Production Facility

  • Clean Rooms with Static Control Area, Antistatic aids in materials handling

  • Machinery & Equipments for SMT (RoHS compliant)

  • Trained manpower (CAD Engineers, QA ,QC teams, Process oriented approach)

  • Proven Process - (IPC-A-610C) standard

  • Combination of MDA , ICT & Functional Test Facility.

  • Rework & Repair Tools.


Factory

  • Octroi free zone at Navi Mumbai

  • Area 6500 sq. ft.

  • Air(Temp/Humidity)controlled,Static Controlled Assembly Area.

  • 15 Km from Nava sheva Sea Port,

  • 25 Km from International Airport

  • 2 hour drive from Software Technology Park Pune

  • More than 1000 Ancillary industries located within 10km diameter MIDC industrial belt

We Expertise In

Among the wide range of products and services offered by us, we especially expertise in meeting the demands of:

  • Miniaturization of PCB assemblies

  • Conversion of through-hole (conventional) assemblies into SMT cards using CAD tools

  • Design & development of Hybrid Microcircuits

  • Electronic Manufacturing Services / Contract Manufacturing


Infrastructure facilities: Established at Octroi free zone at Navi Mumbai, in an area of 6500 sq. ft., the facilities are Air Controlled and well segregated under Assembly Area and Static Controlled Assembly Area. We have with us well developed infrastructure facilities comprising Clean Rooms with Static Control Area, Antistatic aids in materials handling and Machinery & Equipment for SMT.

Other than this, we also have with us facilities for:

  • Trained manpower who have process oriented approach (CAD Engineers, QC teams)

  • Proven Process-(IPC-A-610C) standard

  • Functional test facility

  • Rework & repair tool facility

  • Air conditioned, dust free and humidity controlled rooms

  • Entire production facility equipped with Anti static flooring

  • Static control and material handling aids being used

  • Modern machines & equipment for PCB Assembly work

  • Trained manpower

  • Wave soldering
  • SMT components reflow soldered other than hand soldered/dip/wave soldered

  • Expert prototype assembly team

  • Use of sophisticated equipment like stencil printers

  • Versatile JUKI pick n'place machines

  • Manufacture resource planning (MRP)

Quality Policy

Our well defined quality policy states:

  • The company will strive for total customer satisfaction by providing engineering solutions through Surface Mount Technology (SMT)
  • The company will regularly review the effectiveness of its Quality Management System (QMS) for continual improvement of systems and operations
  • The company will adopt latest technological trends to enhance business operations in high-end technology based products
  • The company will motivate & train competent employees to enhance their technical capabilities
  • The company will maintain an open communication channel with its customers & will carefully monitor their feedback to upgrade Products, Services and Quality Standards
Quality Policy

Packaging Facilities

We have with us well developed packaging facilities that allow us to ensure end products are provided in antistatic bags and static control bubble foam packaging. Other than this, we also have special enclosures with lid covers that are devised to ensure safe delivery of the product. Further, the plastic crates used by us are devised with separators to compartmentalize packing for avoiding finish product damage during transportation stage. During rainy seasons, we also ensure containers are wrapped in plastic covers to avoid entry of moisture.

Quality Objectives

The well defined quality policies stated by our company helps us in achieving the defined objectives of our business policies and production operations. Our quality objectives states:

  • Meticulously follow Quality Management System & ISO9001: 2000 procedures
  • Adapt best manufacturing practices required to satisfy customer’s needs
  • Minimize customer complaints by evaluation of documented data and target for maximum yield by adapting six sigma techniques
  • Effective utilization of Automated machines by installing additional Quality Control equipment for consistency &reliability in processes
  • Use innovation in design and standardize design methods by using state of Art CAD tools to support industries in India & Abroad
Quality Objectives

Clientele

Our consistent approach in offering quality solutions in the embedded and instrumentation field has helped us to offer compatible solutions to our customers. Further, our capability to deliver solutions with custom modifications as well as meeting the demands of repair and maintenance services has also helped us in gaining support from many quality conscious clients.

 

These include:

  • Bhabha Atomic Research Centre (BARC), Trombay
  • Air Force Station, Thane
  • Maxim Peripherals, Mumbai
  • Voltas Limited, Thane
  • Bharat Bijlee Ltd , Navi Mumbai
  • Transasia Biomedicals Ltd, Mumbai
  • Ashida Electronics Pvt. Ltd; Thane
  • Aplab India Ltd. Ltd; Navi Mumbai
  • Siemens Design House
  • Diligent Controls ,Thane
  • Tokheim Kaizen Pvt. Ltd, Navi Mumbai
  • Askinfoteck Limited , Mumbai
  • Emco Limited
  • Micro Technologies
  • Sogo Instruments
  • Techno soft Information Technology
  • Indocen
  • Randox
Clientele

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Why Us?

Some of the factors that distinguish us from our competitors include:

  • Miniaturization - Higher packing density and integration for capability improvement
  • Higher reliability – Thermal Aging and in Burn In test
  • Better performance – Checks on BOM as per ERC, DRC, Conditional Placement, Signal Integrity, EMI/EMC (SI)
  • Modular Approach – Flexibility in maintenance that results to lower costs in service
  • Economics - Reduction in PCB, Components, Assembly and Repair Costing
  • High production volumes – Automated process
  • Quality- Process control through Six Sigma approach

Services

Design & Development

o    Computer Aided Design & Conversion of Conventional Through Hole PCB Assemblies into SMT Cards. Cadence(Allegro) design Suite

o    Quicker evaluation – Separate setup for Prototypes Fabrication, samples for approvals or validation

o    Supply Chain Management - In house stock of wide variety of Surface Mount Devices, inventory management & Scheduling of critical components.

o    Selection of packages & vendors to meet specific end needs in cost & availability of components.

o    Functional Testing, Test-Jig Fabrication, Customized-jigs.

o    Volume production – The state of Art facility equipped with Multi-function Chip Mounter, Conveyorized Reflow & Wave soldering machines.


Our Facility

o    SMT components reflow soldered rather than hand soldered/dip/wave soldered.

o    Expert prototype assembly team.

o    Sophisticated equipment such as stencil printers.

o    Versatile JUKI pick n'place machines.

 

Infrastructure for sourcing

· Technically qualified and efficient purchase team

· Stores equipped with MRP ( Material resource planning ) with wide component data  base

· In house Vendor development program implemented

· Supplier evaluation & records of delivery schedules & quality inward inspection maintained.

· Import of raw material & components through authorized distributors, dealers

· Direct overseas purchase of Critical items

· Sourcing channels established for smaller quantities : Farnell, Mouser, RS components etc.

· Secured storage of Critical components in Humidity / Temperature controlled atmosphere

· Well defined Quality Management System (QMS ) to support systematic

   ∙ Material Flow
   ∙ Data Flow
   ∙ Work Instructions flow


Evaluation of ERP service providers :(Is in progress)


  ∙ Flow charts ready for operations , information work flow
  ∙ Forms & formats devised for data generation
  ∙ Data entered & maintained on desktops at each work stage for easy retrieval of information
  ∙ Questionnaire ,Benchmarks given to ERP vendors to satisfactory demonstrate its the end use.

Quality

In process Quality checks

In process Formats include multiple criteria for compliance to Quality Parameters

The formats flow through out the manufacturing process to monitor defects in the product throughout process cycle

§  inward inspection : of bare PCBs, Components, RM & consumables

§  Process parameters : Dispensing, Stencil printing, Assembly, Temp. profiling of Reflow & wave soldering

§  Final inspection : Criteria include specific customer inputs

§  Testing : 100 % Test parameters tabulated as per Customer test procedures

 

In process Testing set up

Component solderability tests

 Component reliability tests on functional test circuits

 Tailor made pallets to identify missing components

 Validation of Critical Processes viz. Component Placement And Soldering

 In House Test jig fabrication set up for ICT & FCT specific to product test requirements

 Mechanical tooling, fixtures devised to get consistent result during cutting, bending, forming operations


In house Test Jigs fabrication capability

CAD net list , Test Points generation.

Floor planning of physical layout of Test Set Up.

Matching test points & steps as per Test Procedures or sequence.

Placement of Test Pins for bed of nails, fixture fabrication.

CNC data for mechanical fixing of test pins, bed of nails, receptacles, support pins, guides.

Mechanical Assembly of test bench, wire wrapping, harnessing & soldering.

FCT –Instrument Panel, Electrical Measurements & Display.

 ICT -Test programming as per BOM list, measuring parameters.

 Forms or Formats to certify acquired data.

 Pass & Fail report, Register, Log book.


Test Methods : combination of MDA, ICT & FCT

Final Quality checking

Product specific checklist prepared to ensure

Component orientation, height, mechanical dimensions nd tolerance

Adhesion of bulky components to prevent damage due to vibration and transport

Re inspection of rework

Final inspection for Solder quality and manufacturing defects

Verification and approval of Functional Test reports

Traceability : Unique board identification number created

 

Qulity Objectives

  • Meticulously follow Quality Management System & ISO9001: 2000 procedures. Adopt best manufacturing practices required to satisfy the customer needs.
  • Minimize the customer complaints by evaluation of documented data and target for maximum yield by adopting six sigma techniques.
  • Effective utilization of Automated machines by installing additional Quality Control equipment for consistency &reliability in the processes .
  • Use innovation in design & standardize design methods by using state of Art CAD tools to support industries in India & Abroad.

 

Solder Joint Profile (Spider Plot)

Parameters Governing Quality & Reliability of a Solder Joint

Quality Control & Test Equipments

  • Stereo-Zoom Microscopes , Vision Engg, USA
  • Temp. Measuring Instruments , Bonkote, Japan
  • Digital Multi-meters, Bonkote, Japan
  • Oscilloscopes, Phillips, LG Electronics
  • Function Generator, Testronic
  • Visual Inspection Systems, Dynascan
  • Dual Trace Storage Oscilloscope, Tektronix, USA.
  • LCR Meter, Decade L,C,R boxes

Quality Orientation

PLAN- Establish the objectives and processes necessary to deliver results

DOImplement the new processes, often on a small scale if possible

CHECK - Measure the new processes and compare the results against the expected results

ACTAnalyze the differences to determine their cause
Quality Orientation

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Our Quality Assurance

Our Quality Assurance
Our Quality Assurance

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Contact us

Mr. Deepak Sawant (Managing Director)
Electronics Sadan No. 1, Ground Floor, C-19, MIDC, Electronics Zone, Near GTL, Mahape
Navi Mumbai, Maharashtra - 400 710, India
Telephone:  +(91)-(22)-27689177/ 27613528

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