Download - Mannan Shahid Forgings (Pvt)Ltd
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.