Mannan Shahid Forgings (Pvt)Ltd.

Informational Presentationby

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 PROFILE1974 - 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. Dana Italia S.P.A Spicer Off Highway axle Division- Italy

2. Taurus International Corporation – USA3. Crown Automotives Co. – USA4. VBG Ltd.- Fontaine – UK5. USD Formteiltechnik GMBH - Germany6. Sidem N.V. - Belgium

COMPANY PROFILE

Total staff strength is about 750, including :

ManagersEngineersAdministrative staffSkilled WorkersSemi Skilled Workers

Organization Chart

DEVELOPMENT

STORE &

PROCUREMENT

FORGING

PLANT

MACHINING

PLANT

MAINTENANCE QUALITY

ASSURANCE

COMMERCIAL FINANCE ADMINIST-

RATION

CHIEF

EXECUTIVE

DIRECTOR

WELFARE

COMPANY

DOCTOR

WELFARE

OFFICER

Customer – Related Process

Activity Customer CEO Director Manager Development

Puts inquiries Inquiries for Quotation

Receives the enquiry for the offer to quote

Review Reviews the enquiry .The review includes but is not limited to the following points

Proper under standing of the inquiry Availability of machines, Skill, and Material Product features and configuration Recommendations Estimated time for the development Any legal/regulatory requirement

Prepares & reviews the check

sheet for quotation review (CSQR/4.3/01)

Approves the review for quotation

Approval to quote?

Sends regrets to the customer

Approval for Quotation

Prepares and sends the quotation (Q/4.3/05) to the customers

Receives the quotation Follow up Follows up the results of the quotation Records

Keeps the record for the review and also maintains the log

(LBCR/4.3/06)

NO

Yes Prepares the Component Costing Sheet DEV (CCS)/4.3/02

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.

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

OK

OK

CUSTOMER ENQUIRY

QUOTATION

PURCHASE ORDER

DESIGN

DEVELOPMENT

FORGING

HEAT TREATMENT

MACHINING

FINISHING

QUALITY ASSURANCE

PACKING & DISPATCH

CUSTOMER

REVIEW

REWORK

REWORK

REWORK

REWORK

REWORK

FEED BACK

NG

NG

OK

NG

OK

OK

NG

OK

NG

NG

REWORK

NG

OK

OK

Handling of EnquiryReceive customer

Sample/Drawing

Generate own

CAD Drawing

Calculate stock weight part weight and cost of raw material

Identify Manufacturing process

Calculate the cost of Production tools i.e

Die,Fixture&Insp. gauges

Identify the production tools required

Calculate the production

volume in man-hours

Translate man-hours

in cost

Add all costsSubmit Quotation

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

ManufacturingForging of Sample Heat Treatment

Machining of ComponentFinal Inspection

Sample Dispatch to Customer

If any discrepancy

Approval Letter from Customer

Manufacture Pilot lot

Dispatch Pilot lot to Customer

EQUIPMENT LIST

FORGE SHOPLine 1 National Maxi Forging Press- 4000 TonsLine 2 Smeral Forging Press- 2500 TonsLine 3 National Maxi Forging Press- 2000 TonsLine 4,5 National Maxi Forging Press- 1300 Tons – 2 offLine 6 Massey Forging Press- 1200 TonsLine 7 National Maxi Forging Press- 700 TonsLine 8 Massey Forging Press- 600 TonsLine 9 Ajax Forging Press- 500 TonsLine 10,11 Massey Forging Press- 300 Tons – 2 off

EQUIPMENT LISTDIE 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

EQUIPMENT LIST

Machine Shop

CNC Turning & Machining CentersCNC Turret DrillingCopy, Turret & Taper TurningSlot & Spline Milling BroachingHobbingCylindrical & Surface GrindingHorizontal & Vertical MillingSpline & Thread Rolling

EQUIPMENT LIST

Testing & Inspection

CNC CMM (Coordinate Measuring Machine)Magnetic / Ultrasonic Crack DetectionSurface Roughness TestingHardness 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.