Académique Documents
Professionnel Documents
Culture Documents
Date: 30-08-2014
Acknowledgement
During my stay at Forward Gear, I experienced a lot of technical and managerial steps
which are part and partial of industrial field. Forward Gear is a very good growing industry whose
setup has excelled so much that it is now dealing with international brands. I find myself lucky to
have the company of skilled professionals at Forward Gear. I learned several steps which involve
planning, developing, managerial control, cutting, production and quality control. During my
internship period, my supervisors were very cooperative and answered my queries very calmly and
also gave me manuals about organization. Besides their ever going activities, they never got
irritated by my questioning. Due to their help and cooperation, now I can confidently say that I am
fully aware of the functions and activities performed in the ME & CI department of the Forward
Gear. In starting days of my internship period I observed and helped in the activities and tasks
going on in the ME & CI office.
I am really thankful to Engr. Shafique Ahmed and Engr. Tahir Mahmood who
cooperated in an outstanding way. Their friendly behavior, and guiding attitude helped a lot during
the stay. At last I am also thankful to Forward Gear General Manager Hafiz Abdul Qadeer who
allowed me to have great time with great professionals.
TABLE OF CONTENTS
Abstract .............................................................................................................................................................. 5
Chapter No: 01
INTRODUCTION ............................................................................................... 6
CONCLUSION ............................................................................................ 17
List of Figures
Figure 1 Khawaja Masood Akhter ....................................................................................................... 7
Figure 2 Brazuca for Fifa-14 manufactured by Forward Sport ........................................................... 8
Figure 3 Forward Gear Logo ............................................................................................................... 8
Figure 4 Forward Gear Building .......................................................................................................... 8
Figure 5 Team Bag Prepared by FG .................................................................................................. 10
Figure 6 Laptop Bag of Adidas .......................................................................................................... 11
Figure 7 Tennis Bag by Adidas ......................................................................................................... 12
Figure 8 Reebok Laptop Bag ............................................................................................................. 14
Figure 9 School Bag by FG ............................................................................................................... 16
ABSTRACT
It is short report about the activities I learned during my stay at Forward Gear. It is to
record my experience at company and recommendations that may bring some improvements to
company. It covers the History of Forward Gear, its major client Addidas, introduction to the
organization, getting orders from client, Managerial control, planning, materials, production process
and quality control. Each step requires special care, attention, skill and control. I observed each step
very carefully and now here is the summary of all steps. After each step is done with great care
company is also concerned with continuous improvement, on time delivery, best quality and low
price. It has established a special department for continuous improvement and to discover new
better and innovative production techniques, it is called ME & CI department. ME & CI stands for
Manufacturing Excellence and Continuous Improvement. During my internship I was mainly
concerned with this department so I experienced new way of exploring production rate and data
analysis. At the end there are strengths and weaknesses of company and some recommendations
which I think can bring more improvement to Forward Gear.
Chapter No: 01
INTRODUCTION
Chapter No: 02
supplying system, directly to the Factory. All this innovations and continuous modifications made it
possible for Forward to be:
The only hand-stitched ball factory for adidas Group (They make adidas and Reebok balls)
Shipper of approximately 4.7 million balls in2007
The most sophisticated hand-stitched ball manufacturer in the world, with lead time of
maximum 60 days, with 50-60% of the balls shipped out within 30 days
Price reducer between 2002-2008 due to localizing of materials (almost100% of the ball
materials are made in Pakistan now) improving efficiency and
productivity
Producer of 32 panels Thermo bonded balls as of September
2007 in a complete new building on the same compound as the
hand-stitched plant. The capacity has been increased to 25,000
balls in April 2008.Between 60-70% of the workers in the ball
factory could be reduced and in the same way the space in the
building could be saved.
Forward has now become the worlds no 1 hand stitched soccer ball
manufacturer with the capacity of producing 35000 balls/ day providing the low price high quality
in minimum lead time.
Chapter No:3
ORGANIZATIONAL STRUCTURE
3.01.1 Political
Political instability in Pakistan can lead to changes in laws and policies which can be in favor or
against the manufacturing sector.
3.01.2 Economical
Economy of Pakistan is facing issues about employment, inflation, illiteracy, which hinders
business growth.
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3.01.3 Social
Cultural issues can be there but still as there are a number of Technological:
People are highly skilled and Forward Gear can introduce new technology for manufacturing.
3.01.4 Legal
Various laws such as discrimination law, consumer law, antitrust law and employment law can
affect how Forward Gear operates, its costs, and the demand for its products.
3.02 Facilities
3.02.1 Area Covered
Forward Gear having 26,2198 square meter available for manufacturing facilities and 18876 square
meter constructed area consist of 5 large, halls 4halls for production purpose and 1 hall for
development purpose with 24/7backup of 1500KV electric generators
to fulfill the requirements of anytime delivery production order.
3.02.2 Quick Response Orders Production
Forward Gear having capacity of 11,500 bags per day to fulfill the
requirements of heavy orders from the customers like Adidas.
Medical care
Group insurance
Medical allowance
Transportation
Social Security
Medical Facility & Educational facility
Medical leaves
Education allowance
Marriage grant &Death grant
Old age benefits & pension
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"A bag manufacturer targets to produce for all brands in the world."This is the
goal of Forward Gear (Pvt.) Ltd. November 15th, 2007, Forward Gear started its set up and with
adidas as the major customer, the company is moving forward to the goal it set. Forward Gear is the
first bag manufacturer in Pakistan for big brands and it is going to change the whole bag
manufacturing industry in the world. Pakistan is a promising site for the business and the combined
experience, knowledge and technology of Pakistan and Korea will make a difference and it will
shake the world by quality, on-time delivery, price and innovative/future-oriented bag products. It
will be fun for you to watch how Forward Gear is moving forward and how to achieve its goal day
to day, week to week and year to year.
Forward Gear (Pvt.) Ltd. Is committed to create a better working environment for its
employees by implementing and sustaining SA-8000 standard requirements, to provide and ensure
their basic rights. We ensure in educating our workers and suppliers/contractors on the policies and
procedures developed by the companys top management to maintain the
highest ethical standards, conforming to:
Forward Gear (Pvt.) Ltd. Aims to maintain its leading position in bags
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Lean Manufacturing
HSE/SOE Standard
OHSAS 18001 Standards
ISO-14001 Standards
SA-8000 Standards
For us nothing is more important and value able then your life and health. Always
use personal protection equipment at your work places provided by company. Safety gloves,
earplugs, goggles, eye guard, etc. always remember that nothing is as important and value able to
Forward Gear as your health and life. For workers safety Forward Gear apply the following
standards &policies they are:
ISO-14001
SA-8000
HSE (Customer Standard)
SOE (Customer Standard)
Lean Manufacturing
ISO-9000:2000
When orders come into a hand we will check the following things:
In Forward Gear, when employee is hired he introduced the organization, to the policies
and procedures, compensation, benefits, safety and accidental prevention, machine layout, about
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immediate supervisor, etc. in the orientation process an effort is made to acquaint the newly hired
employees with the organizational structure.
3.05.2 Training and Development Policy
Training helps the employees gain the specify the job related skills that ensures effective
performance. In Forward Gear may occur on or off the job. Before off of the training a
comprehensive training is checked out by the human resources department. Then it is handed over
to the relevant department heads. Employee are trained through the lectures given by the
department heads through relevant reading material, and by the department rotation and reading
material is given by the employees of the officer and staff level. Forward Gear is among few
organizations where employees are rotated from one department to another, so that could be
equipped with diversified knowledge and to have through understanding of Forward Gear of the art
corporate culture. Sometimes employees are directly deployed on the seat for which he is hired.
3.05.3 Probation and Confirmation Policy
An employee selected for three month, depending upon his performance. During the
probation period the probationer shall not be any type of facility. During the probationary period the
probationary shall not be entitled any type of leave. In case he earns any leave, it would be
considered without pay. On successful of completion of probationary period an employee shall be
confirmed from the date of his appointment, unless specifically stated otherwise to him in writing.
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3.05 Departments
3.05.1 Data Analysis Department
Data Analysis department of Forward Gear manages all the data of the organization
relating to the material , purchase order, cutting , printing, accessories of the bags. The department
consist of one manager and four employees. The department maintains
the data through different means like gate passes, receipts, and
personal observations. The main duty of the department is to check
whether the production is going on according to the plan and forecast
or not. Data analysis department plays a very key role in the working
of the organization. Means of collecting the data are:
Line leaders
Gate pass
Daily production report
QC report
Output boards
Checkers
Figure 8 Reebok Laptop Bag
Packers
MIR(Material Internal Report)
After collecting the data the department analysis it with the order of the bagand report the
general manager to perform the necessary measures. At the end of the month and after completion
the order the manager of the department has to prepare a report on all of the work that occurs
between that month and order and submit it to the Managing director of the company.
The Development department of forward gear manages all the work relating to developing
of the samples of the new bags. It checks the cost of the bag relating to its profit. The department
consists of 9 employees including one manager in them. The department forecasts the type and
amount of material required to make a bag. Summarizing the work of development department as:
Download ads
Distribution ads and artwork to:
Development office
Design
Costing
Development Hall
Making size table
Making Dummy Sample
Check Material
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Order Material After performing all these steps the bags is manufactured and pass to theQuality
Control department for checking. If it is ok then pass for the order otherwise new sample is
prepared.
The department has to maintain all the records of the employees of the company relating
to their salary, bonuses, rewards and overtime record. The department is also responsible to prepare
the financial plans and financial statements of the company. Summarizing the work of
the department as
The material department in the company plays a very important role. This is because without the
supply of right material at right time we cannot prepare the bag. The duty of the department is to
check all the record of the material used in the preparation of the bag and make the order of the
material that is short before the start of the bag to the supplier. The supplier can be local
or overseas. After ordering the department checks the status of the order and make sure that it
received on time. The department updates about the status of the material to the Managing Director
time to time. The material issued to the material feeders on the basis of MIR report and on demand.
Summarizing the detail of the department as:
The printing department of the company is connected with the cutting hall.
According to the POs of the bags the panels made
and send them to the printing department for the printing. The printing mostly done by the screen.
The department maintains all the record of the printing mostly through the gate passes. The
department submits report time to time to the managing director of the company. Summarizing the
Work as:
Receiving cut panels
Maintain record
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Printing
Dealing with the rejected printing panels
Preparing the daily, weekly and monthly report
The quality control department of the company checks the quality of the
material, printing and the sewing of the bags. The department perform certain tests in the lab to
check the material while the sewing of the bags are check in the line during production. The
employees in the department are hired by the head office of adidas in Sialkot. The minor missing in
the printing is also rejected in the line. The department use both inline and end line inspection.
Summarizing the work of the department as:
Physical checking of Material
Performing tests
Sewing checking
Cut panels
Shade variation
Stitching
Proper trimming
Printing checking
Color shade
Figure 9 School Bag by FG
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Chapter No:4
CONCLUSION
During the stay at different departments I observed following strengths and weaknesses,
4.01 Strengths
During my internship period I observed following strengths of the organization:
4.02 Weaknesses
During my internship period I observed following strengths of the organization:
4.03 Opportunities
4.04 Threats
During my internship period I observed following strengths of the organization:
Cost threats, company can have cost increments due to the electricity rising rates in Pakistan
which may result in loss of order from China because China demands very economical
rates.
Political Threats
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4.05 Recommendations
CNC Cutting machine should be installed in cutting as I have calculated it will be very
beneficial. According to my calculation if CNC fabric cutting is installed it would be 5 times
faster than the conventional cutting and will pay back in 8 months.
If due to some reason, company is not able to install CNC fabric cutting machine, the as a
compensation it must use plotter printing for tracing it would also be beneficial in all ways
and will pay back in 6 months.
There should be proper check on labor as well as on management to avoid the management
politics.
There should be more security of old employees.
There should be hiring of more specialized and skilled employees in printing department.
Promotion should be given bi-annually.
Employee union should be centralized.
Planning should be done to complete the work assigned to workers within working hours to
avoid overtime from labors.
There should be more decentralization in the higher authorities of Forward Gear so that in
absence of MD, there should be no delays in completion of tasks.
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Chapter No: 05
REFERENCES/BIBLIOGRAPHY
http://www.forward.pk/
http://gear.forward.pk/
https://www.google.com/
https://www/wikipedia.com
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