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) вЂ“ Germany To-day вЂ¦. Largest Forging House in Pakistan вЂ“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 вЂ“ USA Crown Automotives Co. вЂ“ USA VBG Ltd.- Fontaine вЂ“ 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 вЂ“ 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. QualityвЂ“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 вЂ“ 2 off 1200 Tons 700 Tons 600 Tons 500 Tons 300 Tons вЂ“ 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 вЂў Salt baths for hardening and tempering, liquid carburizing and nitriding вЂў Salt baths for hardening and tempering of dies вЂў Induction hardening plant (140 KW, 4 KHz & 100 KW, 10 KHz for shafts and spindles EQUIPMENT LIST Finishing Shop вЂў Normalising 1000 kg/hr вЂў Shot blasting 1-6 Tons/Hr. (Batch and continuous type) WELFARE AND PAY PACKAGE Basis вЂў Based on Japanese Management Model : вЂњBetter welfare and pay package ensures a more satisfied work force with greater productivityвЂќ. WELFARE AND PAY PACKAGE Principles вЂў Relieving worker of domestic pressures and enabling whole hearted devotion. вЂў A better pay package to gain longer tenures and reduced training time. WELFARE AND PAY PACKAGE Application вЂў Model initially applied to 25% of work force. вЂў Marked improvement in production levels and reduction in manpower turbulence noted over one year trial period. вЂў In 1990 enhanced welfare and pay package extended to entire work force. вЂў Analysis reveals 27% increase in production levels at an additional cost of 11%. WELFARE AND PAY PACKAGE General вЂў Modern and progressive. вЂў Based on a вЂ�Reward and PunishmentвЂ™ (Carrot and Stick) basis. WELFARE AND PAY PACKAGE Pay and Allowances вЂў Six monthly performance based increment on gross pay and вЂў вЂў вЂў вЂў вЂў вЂў 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 вЂў Marriage grant. вЂў One meal daily during working hours. вЂў Interest free loan up to 2.5 salaries, repayable in 10 вЂў вЂў вЂў вЂў вЂў 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 вЂў Detailed documentation of all factory workers, their parents вЂў вЂў вЂў вЂў 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.