The Research and Development Unit in the IBC was established in March 2004 with the approval of the Ministry of Industries and Mines in order to develop R&D (Research and Development) activities, including development of new products (qualitative and quantitative), enhancing and changing of bearing manufacturing technology, increase in efficiency, cost reductions, and so on.
The Research and Development Unit has been divided into 3 units to meet its responsibilities: project controls, process designing, and technology and designing of products and tools.
In this unit, using MS Project Software, the defined projects in various fields, such as the project of new products, projects for designing and construction of machinery and manufacturing / sub-manufacturing equipments, and improvement projects are controlled and managed.
One of the main targets of research and development is the qualitative and quantitative development of manufactured products (bearings). In this regard, by ten years ago this unit has designed and manufactured the bearings used in the new domestic cars in cooperation with various manufacturing and support units, along with development of automotive products in the domestic car-making factories. In this respect, the bearings used in Pride, (69349/310, 11749/10, and 68149/10), four types of bearings for Peugeot 405 gearbox, AB-40559, 69349A/310, N 41627 H300 (cylindrical roller bearings), and 32005 (taper roller bearings) have been designed in the R&D Unit, and is now manufactured in large scale. It is noteworthy that the different stages of component designing, machinery tools, and controlling devices for these double-row bearings and types of front and rear axles in Peugeot 405 has been conducted in the designing unit of this company.
Also, a number of projects to improve the process of production have been defined, including quality enhancement, reduction in waste, as well as in production cost, automation, and etc, which is now under operation in cooperation with the company's support and manufacturing units. In this regard, designing and making of manufacturing machines, including roller-filling in assembling unit, packaging, and so on is currently undertaken by the project manager.
Process Designing Unit
Regarding the implementation of quality management system in the company, which is called Engineering and Process Designing Unit, is responsible for providing technical documents of quality management system for the company products. For this, all related documents, such as operation and entering control inspection cards during the final production PFMEA (Control plan, OPC, OPS), the main features of a product-process, matrix, layout for manufacturing flow, test plan, and etc., have been provided for all the manufacturing products in this unit under the name of SQA Documents, and has been presented to the qualitative, as well as manufacturing units in a controlled form.
The prepared SQA documents are also sent to the company customers (SAPCO, MEGAMOTOR, NIROOMOHARREKEH, ...) by the controlled approval to ensure the quality of the manufactured products by the customers.
The Unit for Technology and Designing Of Products And Tools
In this unit, using the reverse engineering, a new product (bearing) is designed. For this purpose, a new product, which is sent by the customer for production, is disassembled in this unit after feasibility production stages and the bearing parts, such as internal, as well as external rings, rolling components, and gauge is separated and when an element is provided for every component, the bearing components are provided with a magnitude about 50 times of the initial plan and manufacturing machinery tools are designed after approval. Thus, all the required tools are designed for all the manufacturing devices (initial lathing, ball/roller pressing, gauge pressure, grinding, ring/ball roller, also assembling and packaging). In addition, designing of tools and controlling devices for the new products in various stages of the manufacturing process is also performed in cooperation with the Quality Control Unit in this unit.
In the Design Unit, a plot for all the required tools in the company machinery is also provided. The unit consists of one director of research and development, and two designing and project chairmen which are responsible for providing and designing the above plot.