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. Dana Italia S.P.A Spicer Off Highway axle
Division- Italy
2. Taurus International Corporation – USA
3. Crown Automotives Co. – USA
4. VBG Ltd.- Fontaine – UK
5. USD Formteiltechnik GMBH - Germany
6. 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

COMPANY WELFARE
DOCTOR OFFICER

MACHINING FORGING DEVELOPMENT MAINTENANCE QUALITY

PLANT PLANT ASSURANCE

STORE & COMMERCIAL FINANCE ADMINIST-

PROCUREMENT RATION
 Customer – Related Process
Activity Customer CEO Director Manager Development
Inquiries for Quotation
Puts inquiries
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)
Approval for Quotation
Approves the review for quotation

Approval NO Sends regrets to

to quote? the customer

Yes Prepares the Component

Costing Sheet DEV
Prepares and sends the quotation (CCS)/4.3/02
(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)
 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
CUSTOMER ENQUIRY

QUOTATION DESIGN
NG

OK REVIEW
PURCHASE ORDER
DEVELOPMENT
NG
REWORK
OK

FORGING

OK NG
HEAT TREATMENT
REWOR K
NG
OK
REWORK
OK
MACHINING

NG
REWOR
OK K

FINISHING
NG

REWOR K
OK

QUALITY ASSURANCE
NG
FEED BACK REWORK
OK

PACKING & DISPATCH

CUSTOMER
 Handling of Enquiry
Receive customer
Sample/Drawing

Generate own
CAD Drawing

Calculate stock weight part Identify Manufacturing

weight and cost of raw material process

Calculate the cost of Identify the production

Production tools i.e 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 Jig, Fixture & Insp.

Design gauges Design

Electrode & Die Jig, Fixture & Insp.

Manufacturing gauges Manufacturing

Forging of Sample Heat Treatment

Final Inspection Machining of Component

Sample Dispatch If any discrepancy

to Customer
Manufacture Pilot lot
Approval Letter
from Customer
Dispatch Pilot lot to Customer
 EQUIPMENT LIST
FORGE SHOP
Line 1 National Maxi Forging Press- 4000 Tons
Line 2 Smeral Forging Press- 2500 Tons
Line 3 National Maxi Forging Press- 2000 Tons
Line 4,5 National Maxi Forging Press- 1300 Tons – 2 off
Line 6 Massey Forging Press- 1200 Tons
Line 7 National Maxi Forging Press- 700 Tons
Line 8 Massey Forging Press- 600 Tons
Line 9 Ajax Forging Press- 500 Tons
Line 10,11 Massey Forging Press- 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.