1. Mannan Shahid Forgings (Pvt)Ltd. Informational Presentationby
Shahid Ahmed Khan

2. 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.

3. COMPANY PROFILE 1974 - Established as small forge shop
Pioneered the production of automotive forgings in Pakistan.
Formed a Private Limited Company.
Separate unit for machining.
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.

4. 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.

5. Our Major Clients in Pakistan
COMPANY PROFILE
Our Major Clients in Pakistan
Atlas Honda Motorcycles
Massey Ferguson Tractors
Fiat Tractors

6. International Customers
COMPANY PROFILE
International Customers
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

7. COMPANY PROFILE Total staff strength is about 750, including :
Managers
Engineers
Administrative staff
Skilled Workers
Semi Skilled Workers

8. Organization Chart DEVELOPMENT STORE & PROCUREMENT FORGING PLANT
MACHINING
MAINTENANCE
QUALITY
ASSURANCE
COMMERCIAL
FINANCE
ADMINIST-
RATION
CHIEF
EXECUTIVE
DIRECTOR
WELFARE
COMPANY
DOCTOR
OFFICER

9. Customer – Related Process

10. 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.

11. 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.

12. 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.

13. Manufacturing Process

14. Handling of Enquiry Receive 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
Submit Quotation
Add all costs

15. 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 Manufacturing
Forging of Sample
Heat Treatment
Final Inspection
Machining of Component
Sample Dispatch to Customer
If any discrepancy
Manufacture Pilot lot
Approval Letter from Customer
Dispatch Pilot lot to Customer

16. EQUIPMENT LIST FORGE SHOP
Line National Maxi Forging Press Tons
Line Smeral Forging Press Tons
Line 3 National Maxi Forging Press Tons
Line 4,5 National Maxi Forging Press Tons – 2 off
Line 6 Massey Forging Press Tons
Line 7 National Maxi Forging Press Tons
Line 8 Massey Forging Press Tons
Line 9 Ajax Forging Press Tons
Line 10,11 Massey Forging Press Tons – 2 off

17. 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

18. 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

19. 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.

20. 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

21. EQUIPMENT LIST Finishing Shop Normalising 1000 kg/hr
Shot blasting 1-6 Tons/Hr. (Batch and continuous type)

22. WELFARE AND PAY PACKAGE
Basis
Based on Japanese Management Model :
“Better welfare and pay package ensures a more satisfied work force with greater productivity”.

23. 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.

24. 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%.

25. WELFARE AND PAY PACKAGE
General
Modern and progressive.
Based on a ‘Reward and Punishment’ (Carrot and Stick) basis.

26. 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)

27. 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.

28. 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.

29. Thank you.