THE GENERAL TYRE AND RUBBER

COMPANY OF PAKISTAN.
 CONTENT
• Company outline
• History of the company.
• Growth
• Our Pioneering role.
• Collaboration with Continental AG.
• Relations with main OEMs.
• Development process.
COMPANY OUTLINE
 ORGANIZATION CHART

Chief Executive Officer

Chief Operating Officer

Executive Director Chief Financial

Marketing Officer

General Divisional
Divisional Divisional Divisional
Manager General Manager Head of Internal
Manager Sales Manager Sales Manager
Cooperate Manager Works Central Audit
RM OE/CS Finance
Services Engineering
HISTORY OF THE COMPANY
• Established in 1963 by an American company GENERAL TIRE
INTERNATIONAL COMPANY.(GTIC)
• Production commenced in 1964. Capacity was 120,000 tyres
per annum later on raised to 240,000 per annum.
• GTIC sold all their shares in 1977 to Bibojee Services Ltd but,
retained 10%.
• Technical assistance agreement was signed as well as
permission was given to continue with the Company name and
use the brand name “General”. An amount of royalty had to be
paid annually.
• 1987 GTIC was purchased by Continental AG of Germany.
Conti became 10% owners of GTR.
• More equipment was added to produce radial
passenger car tyres as well as rear tyres for
tractors.
• New equipment for quality control was also
added.
• Equipment for producing steel belted tyres was
also added.
• Plant is continuously upgraded to maintain high
quality and high output.
• During the last three years more equipment has
been added to enhance capacity to produce new
sizes and increase production and improve
quality.

• Equipment like new F270 mixer, second steel

belt line, triplex extruder and presses. A second
tyre uniformity optimiser is added. Talks are
going on to add another F270 mixer as well as
more presses.
GROWTH
 PROD. & SALES GROWTH
2,500,000.00

2,000,000.00

1,500,000.00

1,000,000.00

500,000.00

0.00
2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08

PRODUCTION SALES
OUR PIONEERING ROLE.
• First tyre manufacturing plant.
• First and only one to produce truck and bus tyres
• First and only one to produce rear tyres for
tractors.
• First and only one to produce radial tyres for cars
• First and only to produce FORMULA III racing car
tyres
• First and only one to produce light truck
radial steel belted tyres
• First and only one to produce a million tyres
annually.
• First and only one to have sophisticated
equipment
• First to export automotive tyres.
COLLABORATION WITH
Role of continental in inducting new tyre

• Continental is technology supplier and provides all

technical support to General Tyre Pakistan

• All design and development work is carried out at Conti

design and development center Hanover

• Conti studies the request which is sent by General

Tyre Pakistan for the induction of new size / design
and provides mold drawings , equipments / tooling
drawings and details , compounds and engineering
specifications etc,.
Role of continental in inducting new tyre

• Conti representative is present to monitor all the

development work in General Tyre Pakistan

• Conti experts also visit to General Tyre Pakistan to

help in developing new tyre / design
RELATIONS WITH MAIN OEMs.
We have been giving them tyres since 1985.

We supply them 100% of their demand and have

developed new sizes in the past.

Currently we are developing a new LT radial for

them for introduction by 2008
We established relationship with them since 1993 when we gave the
first radial tyre for their very first production car.

We are meeting 100% of their demand and have developed new sizes
in the past.

Recently we have developed 195 R 14C LTR for the new Toyota Hilux.
Supply will start Oct. 2007.

Currently we are developing new 195/65R15 PCR for them.

 MILLAT TRACTORS LIMITED

We are meeting about 90% of their requirements

of front tyres and 100% of the rear tyres.
Our association dates back two decades.
AL-GHAZI TRACTOR LIMITED

We established relationship in mid-80’s and supply

100% of their requirements of front and rear tractor
tyres.
 HONDA ATLAS CARS

We have been meeting 75% of their demand

mainly because we do not make the size required
for one of their models.
We have been their major supplier since 1994
when they commenced operations.
We are now developing a 195/65R15 tyre for
them.
ADAM MOTORS LTD - KARACHI
REVO 800 145/70R12
REVO 1000 155/70R13
ZABARDAST ECNO 650-16 10PR
ZABARDAST SUPER 650-16 14PR

AL-GHAZI TRACTOR LTD -DERA GHAZI KHAN

FIAT-480 600-16 - 12.4/11-28 6PR
FIAT-480 GHAZI 600-16 - 14.9/13-28 6PR
FIAT 640 750-16 - 16.9/14-30 6PR
DELTA INNOVATIONS LTD - KARACHI
STAR TRUCK 640-13 10PR

DEWAN FAROOQ MOTORS LTD - KARACHI

SANTRO PLUS 1000 CC 155/70R13
HYUNDAI SHEHZORE 650-14 10PR

GHANDHARA INDUSTRIES LTD - KARACHI

ISUZU LIGHT TRUCK 750-16 14PR
ISUZU TRUCK / BUSES 900-20 14PR

GHANDHARA NISSAN DIESEL LTD - KARACHI

NISSAN TRUCKS / BUSES 900-20 14PR / 1100 - 20 16PR
G.M. UNIVERSAL TRACTOR LTD - KARACHI

UNIVERSAL-530 600-16 - 14.9/13-28 6PR

UNIVERSAL-530 750-16 - 16.9/14-30 6PR

HINOPAK MOTORS LTD - KARACHI

HINO COACH & TRUCK 750-16 14PR

HINO TRUCKS / BUSES 900-20 14PR/1000-20 16PR/1100-20 16PR

HONDA ATLAS CARS(PVT)LTD - LAHORE

HONDA CITY 1300 CC 165/80R13

HONDA CITY 1500 CC 185/55R15
HONDA CIVIC 1800 CC 195/65R15
INDUS MOTOR CO. LTD - KARACHI

DAIHATSU CUORE 800 CC 145/70R12

TOYOTA COROLLA 1300 CC 175/70 R14
TOYOTA COROLLA 1800 CC 185/65R14
TOYOTA COROLLA 2000CC 185/65R14
TOYOTA HILUX 195 R 14C

MILLAT TRACTORS LTD - LAHORE

MASSEY FERGUSON -240 600-16 - 12.4/11-28 6PR

MASSEY FERGUSON -260 600-16 - 14.9/13-28 6PR
MASSEY FERGUSON -375 750-16 - 16.9/14-30 6PR
MASSEY FERGUSON -385 750-16 - 18.4/15-30 6PR
MASTER MOTOR CORPORATION LTD - KARACHI
MASTER FOTON 650-16 10PR
MASTER YUEJIN 750-16 14PR

PAK SUZUKI MOTOR CO. LTD - KARACHI

SUZUKI MEHRAN 800 CC 145/70R12
SUZUKI ALTO 1000 CC 145R12
SUZUKI CULTUS 1000 CC 155/80R13
SUZUKI LIANA 1300 CC 185/65R14
SUZUKI LIANA 1600 CC 185/65R14
SUZUKI RAVI PICKUP 450-12 8PR
SUZUKI BOLAN VAN 450-12 8PR
SUZUKI POTOHAR JEEP 175/80-16 6PR
SIND ENGINEERING LTD - KARACHI

DONG FENG 650-16 10PR

DONG FENG 750-16 14PR

SIGMA MOTORS

DEFENDER 750 R 16 10PR

DEVELOPMENT PROCESS
1. ANNOUNCEMENT OF PROJECT LEADER AND
TEAM.

2. DESIGN INPUT
a) PRODUCT REQUIREMENT FROM OEM
b) TYRE DEVELOPMENT CHECK REQUEST SHEET
FROM OEM
c) PATTERN SELECTION BY OEM
d) TYRE CONDITION EQUIPMENT VALUES
e) VEHICLE EQUIPMENT INFORMATION
3. DESIGN OUTPUT

– DIMENSION/PROFILE DEVELOPMENT

– DEVELOPMENT OF MOLD DRAWINGS

– FABRICATION OF PROTO TYPE MOLD

4. PRODUCT DEVELOPMENT

– DEVELOPMENT OF MANUFACTURING SPEC.

– ARRANGEMENT OF RAW MATERIALS.

– DEVELOPMENT OF PROTO TYPE TYRES.

5. VALIDATION & VERIFICATION

– IN HOUSE TESTING
• ENDURANCE
• HIGH SPEED
• TYRE PERFORMANCE TEST
• UNIFORMITY
• DYNAMIC BALANCING
– TECHNICAL EVALUATION OF PRODUCT
6. CONTROL OF DESIGN DEVELOPMENT CHANGES

– IST SAMPLE SHIPMENT TO OEM FOR THEIR

EVALUATION, FEED BACK FROM OEM

7. IF O.K FORMAL APPROVAL REQUIRED FROM

OEM FOR MASS PRODUCTION

8. IF NOT O.K REPEAT STEP 4 TO 6 FOR CHECKING

COUNTER MEASURES
9. RELEASE OF NEW PRODUCT FOR MASS
PRODUCTION

– TYRE RELEASE FOR MASS PRODUCTION

AFTER OEM APPROVAL
 TYRE MANUFACTURING PROCESS
Purchase Raw Materials From Conti Approved Suppliers

Store in RMWH

Testing/Certification QA-LAB

EXTRUSION

BAND Reliability Testing

BUILDING

FABRIC TYRE TYRE

MIXING CALENDERING VULCANIZING
CUTTING BUILDING INSPECTION

Uniformity Evaluation/
BEAD Grading
BUILDING

Finished Goods Ware House

 QUALITY ASSURANCE
QA. LAB:
Raw materials inspection & testing, procesed materials testing during usage/
manufacturing & finished product critical parameters testing to ensure it‘s
reliability.

IN-PROCESS INSPECTION/AUDIT:
To audit critical characteristics of the processes and important parameters of
the product components during manufacturing for conformance to their
procedures / std. practices and specifications respectively.

QUALITY ENGG.:
To conduct problem studies, calibration programme, and provide system,
procedures, sampling plans and out going product standards.
 QUALITY ASSURANCE
UNIFORMITY EVALUATION:

To evaluate finished radial tyres for their unformity levels and to grade them
accordingly.

X – RAY INSPECTION:
To check cured radial tyres for hidden anomolies and provide feed back to get
the corrective action implemented .

RELIABILITY TESTING:
To certify the overall process and tyre design relibality by testing them under
stringent dynamic test methods.
High Speed = F-4426(FMVSS – 109), F-4435(ECE – 30)
Endurance = F-4428(FMVSS – 109)
 QUALITY ASSURANCE
TESTING FACILITY FOR RAW MATERIALS
(QUALITY ASSURANCE LAB.)
EQUIPMENT: TO EVALUATE:
RHEOMETER MDR-2000 TORQUE Vs TIME
(RHEOMETER PROPERTIES)
INSTRON TESTER MODEL-3365 BREAKING STRENGTH,
ELONGATION, ADHESION,
MODULUS, TENSILE STRENGTH,
SINGLE CORD STIFNESS.
F. T. I. R. SPECTROMETER POLYMER RATIO IN THE CURED
RUBBER.
MOONEY VISCOMETER MV-2000 TO CHECK MOONEY VISCOCITY OF
MASTER & FINISHED BATCHES.
SURFACE AREA ANALYSER SURFACE AREA OFZINC OXIDE.
WALLACE RAPID PLASTIMETER ORIGINAL PLASTISITY& PLASTICITY
RETENTION IN NATURAL RUBBER.
D.B.P ABSORPTOMETER ABSORPTION RATE OF OIL IN CARBON
PELLET HARDNESS TESTER HARDNESS OF CARBON BLACKS.
 QUALITY ASSURANCE
TESTING FACILITY FOR END PRODUCT

EQUIPMENT: PURPOSE:
TIRE UNIFORMITY OPTIMIZER (TUO) TIRE UNIFORMITY
FORCES EVALUATION

DYNAMIC BALANCING MACHINE TIRE DYNAMIC

IMBALANCE VALUES
DETERMINATION
AIR RETENTION TEST UNIT AIR RETENTIVITY TEST
ON RADIAL TIRES
TIRE X-RAY MACHINE AIR ANOMALIES & STEEL
BELTS IMPERFECTIONS
PULLEY WHEEL ENDURANCE AND
HIGHSPEED TESTING
 QUALITY ASSURANCE
SAFETY STANDARDS.

HIGH SPEED TEST FMVSS 139

ENDURANCE TEST FMVSS 119

CERTIFICATION OF FITNESS OF TYRES

ALL THE TESTS DISCUSSED HERE CERTIFIES THE FITTNESS

OF TIRES FOR USAGE.
 Manufacturing process & Quality Control at
Manufacturing Process
Proto & Mass and Quality
Production Scale Control
SYMBOLS USED FOR IDENTIFICATION

= Q.A. INPROCESS AUDIT

CEMENT = LAB TETSING (100%)
HOUSE = STATISTICAL PROCESS CONTROL
= TOOL & GAUGE CONTROL PROGRAM
= OPERATOR AUDIT
= PULLEY WHEEL TESTING
= 100% INSPECTION
BEAD FORMING = SURVEY
PREPARATION = TRACEABILITY
RMWH = 2ND INSPECTION BY Q.A
INCOMING RAW = AIR RETENTION TEST
MATERIAL
4 ROLL
CALENDER
STOCK RADIAL TIRE TIRE RADIAL TIRE FINAL
PREPARATION BUILDING LUBRICATION CURING FINISH

STEELASTIC

BULGE/INDENT. TIRE DYNAMIC

UNIT UNIFORMITY BALANCING
OPTIMIZER
TRIPLEX
MIXING EXTRUDER
2ND
INSPECTION
BY Q.A.
3 ROLL
CALENDER
FINISHED
GOOD
WARE HOUSE
THANK YOU