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. 2.

Atlas Honda Motorcycles 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 USA Crown Automotives Co. USA VBG Ltd.- Fontaine 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

COMPANY DOCTOR

WELFARE OFFICER

MACHINING PLANT

FORGING PLANT

DEVELOPMENT

MAINTENANCE

QUALITY ASSURANCE

STORE & PROCUREMENT

COMMERCIAL

FINANCE

ADMINISTRATION

Customer Related Process

Activity
Inquiries for Quotation

Customer
Puts inquiries

CEO

Director

Manager Development

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 to quote? Yes

NO

Sends regrets to the customer Prepares the Component Costing Sheet DEV (CCS)/4.3/02

Prepares and sends the quotation (Q/4.3/05) to the customers Receives the quotation Follow up Records Follows up the results of the quotation 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.

QualityOur 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
REWORK

HEAT TREATMENT
NG REWORK OK OK

MACHINING
NG OK REWOR

FINISHING
NG REWORK

OK QUALITY ASSURANCE
NG

FEED BACK OK

REWORK

PACKING & DISPATCH CUSTOMER

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
Die,Fixture&Insp. gauges

Identify Manufacturing process Identify the production tools required

Calculate the production volume in man-hours Submit Quotation

Translate man-hours in cost Add all costs

Preparation of Sample & Pilot lot

Receive Purchase order from customer Designing Phase CAD. CAM & Die Design Electrode & Die Manufacturing Forging of Sample Final Inspection Sample Dispatch to Customer Approval Letter from Customer Jig, Fixture & Insp. gauges Design Jig, Fixture & Insp. gauges Manufacturing Heat Treatment
Machining of Component

If any discrepancy 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 Press- 4000 Tons Smeral Forging Press2500 Tons National Maxi Forging Press- 2000 Tons National Maxi Forging Press- 1300 Tons 2 off Massey Forging Press1200 Tons National Maxi Forging Press- 700 Tons Massey Forging Press600 Tons Ajax Forging Press500 Tons Massey Forging Press300 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.