1 Mannan Shahid Forgings (Pvt)Ltd. Informational Presentation byShahid Ahmed Khan
2 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.
3 COMPANY PROFILE 1974 - Established as small forge shop Pioneered the production of automotive forgings in Pakistan.Formed a Private Limited Company.Separate unit for machining.Certified for ISO 9001:1994 (AIB Vincotte) - Belgium.2002 -Certified for ISO 9001 : 2000 (TUV) – GermanyTo-day …. Largest Forging House in Pakistan –exporting approximately 40% of its out-put.
4 COMPANY PROFILEWe 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.
5 Our Major Clients in Pakistan COMPANY PROFILEOur Major Clients in PakistanAtlas Honda MotorcyclesMassey Ferguson TractorsFiat Tractors
6 International Customers COMPANY PROFILEInternational CustomersDana Italia S.P.A Spicer Off Highway axle Division- ItalyTaurus International Corporation – USACrown Automotives Co. – USAVBG Ltd.- Fontaine – UKUSD Formteiltechnik GMBH - GermanySidem N.V. - Belgium
7 COMPANY PROFILE Total staff strength is about 750, including : ManagersEngineersAdministrative staffSkilled WorkersSemi Skilled Workers
8 Organization Chart DEVELOPMENT STORE & PROCUREMENT FORGING PLANT MACHININGMAINTENANCEQUALITYASSURANCECOMMERCIALFINANCEADMINIST-RATIONCHIEFEXECUTIVEDIRECTORWELFARECOMPANYDOCTOROFFICER
10 Quality PolicyTo 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.
11 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.
12 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.
14 Handling of Enquiry Receive customer Sample/Drawing Generate own CAD DrawingCalculate stock weight part weight and cost of raw materialIdentify Manufacturing processCalculate the cost ofProduction tools i.eDie,Fixture&Insp. gaugesIdentify the production tools requiredCalculate the productionvolume in man-hoursTranslate man-hoursin costSubmit QuotationAdd all costs
15 Preparation of Sample & Pilot lot Receive Purchase order from customerDesigning PhaseCAD. CAM & Die DesignJig, Fixture & Insp. gauges DesignElectrode & Die ManufacturingJig, Fixture & Insp. gauges ManufacturingForging of SampleHeat TreatmentFinal InspectionMachining of ComponentSample Dispatch to CustomerIf any discrepancyManufacture Pilot lotApproval Letter from CustomerDispatch Pilot lot to Customer
16 EQUIPMENT LIST FORGE SHOP Line National Maxi Forging Press TonsLine Smeral Forging Press TonsLine 3 National Maxi Forging Press TonsLine 4,5 National Maxi Forging Press Tons – 2 offLine 6 Massey Forging Press TonsLine 7 National Maxi Forging Press TonsLine 8 Massey Forging Press TonsLine 9 Ajax Forging Press TonsLine 10,11 Massey Forging Press Tons – 2 off
17 EQUIPMENT LIST DIE SHOP & TOOL ROOM CNC Milling Vertical milling and BoringPC based CAD / CAMCopy MillingSpark Erosion Die Sinking (30 Amps, 50 Amps & 100 Amps.)Jig boring & GrindingHorizontal surface and cylindrical grindingTool & cutter grinders
20 EQUIPMENT LIST Heat Treatment Shop Salt baths for hardening and tempering, liquid carburizing and nitridingSalt baths for hardening and tempering of diesInduction hardening plant (140 KW, 4 KHz & 100 KW, 10 KHz for shafts and spindles
21 EQUIPMENT LIST Finishing Shop Normalising 1000 kg/hr Shot blasting 1-6 Tons/Hr. (Batch and continuous type)
22 WELFARE AND PAY PACKAGE BasisBased on Japanese Management Model :“Better welfare and pay package ensures a more satisfied work force with greater productivity”.
23 WELFARE AND PAY PACKAGE PrinciplesRelieving worker of domestic pressures and enabling whole hearted devotion.A better pay package to gain longer tenures and reduced training time.
24 WELFARE AND PAY PACKAGE ApplicationModel 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%.
25 WELFARE AND PAY PACKAGE GeneralModern and progressive.Based on a ‘Reward and Punishment’ (Carrot and Stick) basis.
26 WELFARE AND PAY PACKAGE Pay and AllowancesSix 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)
27 WELFARE AND PAY PACKAGE Pay and AllowancesMarriage 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.
28 WELFARE AND PAY PACKAGE MedicalDetailed 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.