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Mannan Shahid Forgings

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Mannan Shahid
Forgings (Pvt)Ltd.
Informational Presentation
by
Shahid Ahmed Khan
TABLE OF CONTENTS
Company Profile.
Organization Chart.
Customer Related Process.
Quality Policy.
Quality Our Commitment.
Trade Offer.
Manufacturing Process.
Handling of Enquiry.
Preparation of Sample & Pilot Lot.
Equipment List.
Welfare and Pay Package.
COMPANY PROFILE
1974 - Established as small forge shop
1984 - Pioneered the production of automotive forgings in
Pakistan.
1989 - Formed a Private Limited Company.
1998 - Separate unit for machining.
1999 - Certified for ISO 9001:1994 (AIB Vincotte) Belgium.
2002 -Certified for ISO 9001 : 2000 (TUV) – Germany
To-day …. Largest Forging House in Pakistan –exporting
approximately 40% of its out-put.
COMPANY PROFILE
We specialize in Forged, heat treated and
machined components based on in-house design
and development of forging dies, machining
jigs & fixtures,gauges and manufacturing
processes..
Presently manufacturing components for Cars,
Trucks, Off Highway Axles, Agricultural
Tractors, Motor Cycles, Fifth Wheels and
Industrial Conveyor systems.
COMPANY PROFILE
Our Major Clients in Pakistan
1.
Atlas Honda Motorcycles
2.
Massey Ferguson Tractors
3.
Fiat Tractors
COMPANY PROFILE
International Customers
1.
2.
3.
4.
5.
6.
Dana Italia S.P.A Spicer Off Highway axle
Division- Italy
Taurus International Corporation – USA
Crown Automotives Co. – USA
VBG Ltd.- Fontaine – UK
USD Formteiltechnik GMBH - Germany
Sidem N.V. - Belgium
COMPANY PROFILE
Total staff strength is about 750, including :
Managers
Engineers
Administrative staff
Skilled Workers
Semi Skilled Workers
Organization Chart
CHIEF
EXECUTIVE
DIRECTOR
WELFARE
MACHINING
FORGING
PLANT
PLANT
STORE &
PROCUREMENT
COMPANY
WELFARE
DOCTOR
OFFICER
DEVELOPMENT
MAINTENANCE
QUALITY
ASSURANCE
COMMERCIAL
FINANCE
ADMINISTRATION
Customer – Related Process
A ctivity
In q uiries for Q uotation
C u stom er
CEO
D irector
M an ager D evelop m en t
P uts in quiries
R eceives th e en quiry for th e offer
to quote
R eview
R eview s th e en quiry .T h e review in cludes but is n ot lim ited to th e follow in g poin ts
п‚·пЂ P roper un der stan din g of th e in quiry
п‚·пЂ A vailability of m ach in es, S kill, an d M aterial
п‚·пЂ P roduct features an d con figuration
п‚·пЂ R ecom m en dation s
п‚·пЂ E stim ated tim e for th e developm en t
п‚·пЂ A n y legal/regulatory requirem en t
P repares & review s th e ch eck
sh eet for quotation review
(C S Q R /4.3/01)
A p p roval for Q uotation
A pproves th e review for quotation
A pproval
to quote?
NO
S en ds regrets to
th e custom er
Yes
P repares an d sen ds th e quotation
(Q /4.3/05) to th e custom ers
R eceives th e quotation
F ollow up
F ollow s up th e results of th e quotation
R ecord s
K eeps th e record for th e review
an d also m ain tain s th e log
(L B C R /4.3/06)
P re p a re s th e C o m p o n e n t
C o stin g S h e e t D E V
(C C S )/4 .3 /0 2
Quality Policy
To aggressively develop, manufacture and market our
products to domestic and foreign clients, achieving highest
level of customer satisfaction through:
Consistently meeting or exceeding customer requirements.
Time bound deliveries.
Concentrating our resources on designing and building quality
into our products and services.
Continuously improving process controls in all areas of our
business.
Encouraging our suppliers to enhance input quality.
Attracting, retaining and developing motivated quality
performers.
Compliance to the legal and regulatory requirements applicable to
our products.
Quality–Our Commitment
To achieve highest level of Customer
satisfaction through continuous improvement in
our products and service.
Implementing SPC to minimize rejections
during manufacturing.
Identify necessary and avoidable costs.
Set targets to reduce avoidable costs.
Trade Offer
Customer oriented procedure for undertaking
business.
Response to enquiries within 72 hours.
Development process starts immediately on
approval of quotation.
The product is developed at our Risk and Cost.
Tooling cost is charged to customer upon
approval of sample.
Manufacturing Process
C U S T O M E R E N Q U IR Y
D E S IG N
Q U O T A T IO N
NG
R E V IE W
OK
PURC HA SE O RD E R
D E V E LO PM E N T
NG
REW ORK
OK
F O R G IN G
NG
OK
HEA T TREA T M EN T
REW ORK
NG
OK
REW ORK
OK
M A C H IN IN G
NG
REW OR
K
OK
F IN IS H IN G
NG
REW ORK
OK
Q U A L IT Y A S S U R A N C E
NG
FE E D BA C K
REW ORK
OK
P A C K IN G & D IS P A T C H
C UST O M E R
Handling of Enquiry
Receive customer
Sample/Drawing
Generate own
CAD Drawing
Calculate stock weight part
weight and cost of raw material
Calculate the cost of
Production tools i.e
Identify Manufacturing
process
Identify the production
tools required
Die,Fixture&Insp. gauges
Calculate the production
Translate man-hours
volume in man-hours
in cost
Submit Quotation
Add all costs
Preparation of Sample &
Pilot lot
Receive Purchase
order from customer
Designing Phase
CAD. CAM & Die
Design
Jig, Fixture & Insp.
gauges Design
Electrode & Die
Manufacturing
Jig, Fixture & Insp.
gauges Manufacturing
Forging of Sample
Heat Treatment
Final Inspection
Machining of Component
Sample Dispatch
to Customer
If any discrepancy
Approval Letter
from Customer
Manufacture Pilot lot
Dispatch Pilot lot to Customer
EQUIPMENT LIST
FORGE SHOP
Line 1
Line 2
Line 3
Line 4,5
Line 6
Line 7
Line 8
Line 9
Line 10,11
National Maxi Forging PressSmeral Forging PressNational Maxi Forging PressNational Maxi Forging PressMassey Forging PressNational Maxi Forging PressMassey Forging PressAjax Forging PressMassey Forging Press-
4000 Tons
2500 Tons
2000 Tons
1300 Tons – 2 off
1200 Tons
700 Tons
600 Tons
500 Tons
300 Tons – 2 off
EQUIPMENT LIST
DIE SHOP & TOOL ROOM
CNC Milling Vertical milling and Boring
PC based CAD / CAM
Copy Milling
Spark Erosion Die Sinking (30 Amps, 50 Amps &
100 Amps.)
Jig boring & Grinding
Horizontal surface and cylindrical grinding
Tool & cutter grinders
EQUIPMENT LIST
Machine Shop
CNC Turning & Machining Centers
CNC Turret Drilling
Copy, Turret & Taper Turning
Slot & Spline Milling
Broaching
Hobbing
Cylindrical & Surface Grinding
Horizontal & Vertical Milling
Spline & Thread Rolling
EQUIPMENT LIST
Testing & Inspection
CNC CMM (Coordinate Measuring Machine)
Magnetic / Ultrasonic Crack Detection
Surface Roughness Testing
Hardness Testing (Rockwell & Brinell)
Air & Dial Gauges, Micrometers & Verniers
etc.
EQUIPMENT LIST
Heat Treatment Shop
• Salt baths for hardening and tempering, liquid
carburizing and nitriding
• Salt baths for hardening and tempering of dies
• Induction hardening plant (140 KW, 4 KHz &
100 KW, 10 KHz for shafts and spindles
EQUIPMENT LIST
Finishing Shop
• Normalising 1000 kg/hr
• Shot blasting 1-6 Tons/Hr. (Batch and
continuous type)
WELFARE AND PAY PACKAGE
Basis
• Based on Japanese Management Model :
“Better welfare and pay package
ensures a more satisfied work force
with greater productivity”.
WELFARE AND PAY PACKAGE
Principles
• Relieving worker of domestic pressures and
enabling whole hearted devotion.
• A better pay package to gain longer tenures and
reduced training time.
WELFARE AND PAY PACKAGE
Application
• Model initially applied to 25% of work force.
• Marked improvement in production levels and
reduction in manpower turbulence noted over
one year trial period.
• In 1990 enhanced welfare and pay package
extended to entire work force.
• Analysis reveals 27% increase in production
levels at an additional cost of 11%.
WELFARE AND PAY PACKAGE
General
• Modern and progressive.
• Based on a �Reward and Punishment’ (Carrot
and Stick) basis.
WELFARE AND PAY PACKAGE
Pay and Allowances
• Six monthly performance based increment on gross pay and
•
•
•
•
•
•
allowances.
12.5% of company profit distributed as bonus, half based on
gross pay and half based on performance.
Special increments for enhancement of qualifications.
Attendance allowance.
Conveyance allowance for privately owned Car/Motorcycle.
School fees for a maximum of 4 children.
Child allowance on a diminishing scale.
(Continued)
WELFARE AND PAY PACKAGE
Pay and Allowances
• Marriage grant.
• One meal daily during working hours.
• Interest free loan up to 2.5 salaries, repayable in 10
•
•
•
•
•
installments.
Motorcycle and Car loan up to 75% of cost of vehicle
purchased. Repayable in 5 years.
Life and medical insurance.
Employees Old-Age Benefits.
Social Security.
Labour department grants.
WELFARE AND PAY PACKAGE
Medical
• Detailed documentation of all factory workers, their parents
•
•
•
•
and families specially those with ailments of a permanent
nature.
In house doctor and medicine facility.
Personal attention to all patients requiring specialist treatment.
Follow up action and care of long term/permanent patients.
Pre and post-natal care.
Thank you.
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