ELECTRO-MECHANICAL ASSEMBLY

Working closely with our customers ITC Business Process Outsourcing has built up considerable experience in product development ranging from printed circuit board population, cable and harness assembly and electro mechanical assembly. Electro-mechanical assembly operation covers cabinet and chassis wiring and assembly, with full testing of the finished product. We also offer a large supplier base for metalwork and finishing services.

PLASTIC INJECTION MOLDING

Fully integrated, tooling, moulding, finishing and assembly operations enables ITC Business Process Outsourcing to deliver superior value to our customers, while our ISO Certified quality system assures consistent product to meet demanding production requirements.

ITC-BPO Ltd offers a wide range of moulding and extruding for engineering thermoplastics and elastomers, with press ranges covering 20 to 1000 tonne. We have the expertise in strategic locations to meet demands for cost competitive components in global markets. We offer worldwide tool procurement, the design and supply of multiple tools for any one finished product and can incorporate a wide array of different components too.

From basic inception we have the ability to design and develop engineering solutions utilising almost every conceivable type of thermoplastic or elastomer. Mould flow and mould cool analysis produce vital data for product optimisation, further refined through stress analysis and resulting in the most accurate and rapid tool and product design.

Having satisfied the basic design and performance parameters, the project team will break the project down into areas of specialisation such as tooling, automation, painting and assembly. We ensure advanced quality planning processes are used to review every facet of our customer’s needs, delivering a systematic, structured and effective approach.


FRP STRUCTURES

FRP is unique amongst materials of construction in that the fabricator actually makes the material. Whether making roof sheeting, chemical tanks, pipes, silos, buildings, vehicle bodies or boats, our suppliers are among the leading suppliers of FRP and GRP in India. A range of fibre glass pultruded FRP structural sections such as rods, tubes, flats, angles, channels, beams and glass epoxy sections, studs and nuts for HT switch gear and transformer industry are also available.


SHEET METAL FABRICATION

We provide a wide range of equipment and capabilities from 10 tons to 600 ton presses offering precision stampings. Mechanical and hydraulic presses of varied sizes are utilized to match the appropriate equipment to product needs. Whether Arc Welding, MIG Welding, TIG Welding or MIG Brazing, our Indian partner has demonstrated capabilities in demanding precision stainless steel assemblies such as chemical containers, pressure vessels and storage equipment.

ITC-BPO Ltd offers a wide range of equipment with the capabilities to undertake large forming of precision sheet metal products. Our punching and cutting capabilities of sheet metal include equipment with both CNC laser and punching capabilities, adding flexibility to our fabrication schedule.

CNC presses and conventional punch presses from 30 to 1000 ton capacities provide manufacturing capabilities in materials ranging from 0.5mm thick to 5mm thick.

Customers requiring lower volumes have the availability to work with our small to medium sized business units who are only too happy to focus their efforts in this field. CNC punching programs are generated from customer’s own data files, or designs provided by our own product.

ITC-BPO Ltd has the ability to design and build stamping tools to help reduce production costs depending on the volume and tolerance needs of the product. We specialize in both high and low volume metal stamping production using a variety of materials that range from 0.5mm to 5mm thick. Hard tool configurations can take the form of inexpensive punching or forming dies, to very large complex fully progressive tools, important processes necessary to drive piece part costs down and to meet tight tolerance requirements.

For optimum time to market considerations, ITC-BPO Ltd has established a tool building network of suppliers around India who are receiving and converting our CAD tool designs into a machine tool language. Our commitment to a low cost tooling solution is evident with our expansion into the global market.

PRECISION NC MACHINING AND GEAR CUTTING

Our specialised services in machining and gear cutting support a wide range of markets - transmission parts such as gear blanks and shafts, power train parts, input, output and countershafts, half shafts and axle shafts. Finished component diameter range from 40 mm to 550 mm.

Product Category:

• Transmission parts such as gear blanks and shafts

• Power train parts: input, output and countershafts, half shafts, prop. shafts, axle shafts

• Finished component diameter: 40 mm to 550 mm (approx)

• Finished component weight range : 0.5 Kg to 5 kg (approx)

Process Technology:

• Machining technology such as CNC turning, CNC milling, gear hobbing, broaching, rolling, grinding

• Heat treatment – hardening and tempering, annealing, induction hardening, case hardening

• Surface finishing such as Ni-Cr plating, hard chrome plating, Zn plating, phosphatizing, etc.

Material Specifications:

• Materials used from hot forging, hot extrusion, bar stock and cold forging

• Low, medium and high carbon steel

• Alloy steel such as 16MnCr5, 20MnCr5. 17Cr3 etc

Gear Primary Driven		Boss Movable Driven
	Material : C45 Process : Hot Forged, Machined Direct Drilling and Boring		Material : C45 Process : Bar Stock Machined Cam profiles are maintained by using a special indexing fixture in vertical machining centre
Ring Gear		Hydraulic Pistons
	Material : C55 Process : Hot Forged, Machined, Gear cut & induction hardened.		Material : CK45 Process :Bar stock machined, Hardened & tempered
Cam, Rear Brake		Lower Bracket
	Material : C45 Process :Bar Stock machined, serration rolled & Nickel plated  Head milling.		Material :En 32B/C20 Process : Hot Forged, Machined, tube press fit & welded

FORGINGS AND CASTINGS

As engineering specialists, ITC- BPO Ltd offers extensive experience in sourcing component requirements. We understand how to best apply metal forming processes in order to meet our clients’ requirements. We regularly help clients to take advantage of the unique advantages in dealing in India and Taiwan. For example:

Tooling lead times can often be shorter in India than in Western Europe due to 24/7 working

Higher volume processes that offer better dimensional, mechanical and cost advantages can often be applied to lower volume applications due to reduced set up rates 

Our foundries or forges have all the necessary facilities for effective quality control:

Micro Hardness Testing

Metallagraph Analyzers

Plasma Spectrometers

Tensile Testing

Casting processes including Sand Casting, Low Pressure Die Casting, High Pressure Die Casting, Investment Casting

Materials including various grades of Cast Iron – Grey & SG, Steel Castings, Aluminium Castings, High Alloy Castings and Stainless Steel

Forging processes including Drop Forging / Hot Forging, Cold Forging

Materials including various grades of Steel, Aluminium, Stainless Steel and Copper

TOOL MAKING

Extensive expertise in the manufacture and moulding of plastic injection mould tools for new, pre-production or low volume products. Mould tools can be manufactured for single or multi-cavity production and to operate fully automated, semi automated or to incorporate inserts which are hand loaded by an operator.

In conjunction with working very closely with our customers the project management process can include rapid prototyping (using the latest solid modelling techniques), 3D mould tool design, mould flow analysis, polymer selection, tool production, tool trialing, QC compliance through to full clean room assembly line production - all engineered and designed according to our clients’ requirements and the complexity of the part.


PCB SMT ASSEMBLY

We offer a complete package of bare board and component procurement for through hole and surface mount technology, and fully automated pick and place equipment capable of placing 4000 components per hour from 0402 through to QFP and BGA. Our production area is able to handle pre-production, small batch and volume production runs. All finished assemblies are given dedicated functional testing to customer specification.

Our consortium companies are located in the international acclaimed technology districts of Bangalore, India and provide electronic solutions to Original Equipment Manufacturers (OEMs) & Original Design Manufacturers (ODMs) in diverse industries.

With a proactive approach to current and future challenges, we ensure that the product meets quality and reliability requirements. High technology and sophisticated equipment is used and constantly upgraded to design and develop the products.

8 Bit microcontrollers (Microchip and Motorola) based hardware and software design.

Component procurement: Direct import & clearing capabilities, sourcing through local vendors, distributors and manufacturers, good vendor base for mechanical and electromechanical components.

Design and manufacturing capabilities: PCB design, in-house PCB design up to 6 layers, development of product concepts and specifications, 2D mechanical design & documentation with AutoCAD, CorelDraw based concepts and user interface design, detailed 3D design through Solid Works.

   


CABLE HARNESS ASSEMBLY

BPO-ITC Ltd specialises in the manufacture of a huge range of harness assemblies, including ribbon, multicore and network looms. Supplying the automotive, commercial vehicle and leisure industries, we have state of the art cut and strip equipment and a variety of semi automated termination equipment covering Molex, AMP, JST and ITT crimps. All finished assemblies are fully tested and labelled according to our customers’ requirements.

We offer a range of wiring harness manufacturing capabilities essential for all automobiles, FMCG products and industrial application. We are equipped to meet the global competition and provide timely delivery while maintaining product quality.

Manufacturing facility includes state of the art machines required for wire harnessing contained in 40,000 Sq Ft of production space, supporting a process layout for smooth flow of materials. All facilities are certified to ISO/TS 16949-2002

Machines and equipment include wire cutting and stripping, toggle presses, wire stripping & twisting, wire cutting, stripping & crimping machines, semi automatic crimping, solder bath with thermo control applicators for all applications and electric ovens for post processing.