Macro-Level Process Flow

In the macro-level process flow, we will be discussing the organizational or interdepartmental

process flow. The organizational process flow starts from the sales department. In sales
departments, sales managers are responsible for order generation and increasing the market base.
The sales team has operations managers as well as exports managers. They are taking orders
from the local as well as international market. The sales department is linked with the planning
department. The general sales manager is communicating the sales numbers to the Planning
manager. The planning department will work on the sales forecast and actual orders taken by the
salespeople. The planning department is linked to the procurement as well as the production
department. The planning managers will tell procurement managers for procuring the raw
materials depending upon the sales numbers. On the other hand, the planning manager is
responsible for communicating the production plan 1 day prior to the actual production so that
the production department can do all the preparations. Depending upon the production plan given
by the planning department, the production department starts its operations. The production
department constitutes of the alloy blending and molding sections. The production department is
then linked to the storage department which is storing the final product that is batteries. The
storage department is also responsible for transporting the batteries to the local distributors.
However, for international distributors, Pakistan Accumulators use brokers and good transport
companies.
 Sales
Department

Planning
Department

Procurement Production Storage

Department Department Department
The average production run is 10 to 15 days when they have excess raw material and idle
machinery. Plant utilization is 80 to 85% with buffer work in process inventory of 1 week.

The Sundays are off for the production department. The production department is aware of the
overtime requirements depending upon the production plan by the planning department. In case
of excess production, an extra shift is added to the process.

The assembly line workers have only 2 shifts while moulding & casting section workers (who
are making battery components) has 3 shifts.

The labour for the production department is outsourced. However, the HR, health 7 safety,
accounts, store, quality check, planning and production executive are hired by the company on
regular and permanent basis.

The process is semi-automatic. They are using men as well as machines.