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Title: Internship Report

Submitted To: HR Manager Forward Gear Sialkot


Submitted By: Awais Ahmed
Department: School of Architecture & Design
Bachelor of Product & Industrial Design
University of Engineering & Technology, Lahore

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

1.01 Background of the study ........................................................................................................................ 6


1.02 Purpose of Study .................................................................................................................................... 6
1.03 Scope of Study ....................................................................................................................................... 6
1.04 Objectives of Study ................................................................................................................................ 6
Chapter No: 02

OVERVIEW OF THE ORGANIZATION ................................................................... 7

2.01 Historical Background ........................................................................................................................... 7


2.01.01 Forward Group Pvt. Limited ......................................................................................................... 7
2.02 Forward Gear Pvt. Ltd. ...................................................................................................................... 8
2.02.1 Introduction of Forward gear: ......................................................................................................... 8
2.02.2 Business volume and number of employees: .................................................................................. 8
2.03 Vision Statement .................................................................................................................................... 9
Chapter No:3

ORGANIZATIONAL STRUCTURE .................................................................................. 9

3.01 PESTL Analysis ..................................................................................................................................... 9


3.01.1 Political ............................................................................................................................................... 9
3.01.2 Economical ......................................................................................................................................... 9
3.01.3 Social................................................................................................................................................. 10
3.01.4 Legal ................................................................................................................................................. 10
3.02 Facilities ............................................................................................................................................... 10
3.02.1 Area Covered ................................................................................................................................ 10
3.02.2 Quick Response Orders Production .............................................................................................. 10
3.02.3 Production Capacity ...................................................................................................................... 10
3.03 Employees Facilities ............................................................................................................................ 10
3.04 POLICIES AND ACHIEVMENTS ..................................................................................................... 11
3.04.1 Social accountability policy .......................................................................................................... 11
3.04.2 Environment policy ....................................................................................................................... 11
3.04.3 Quality Policy ............................................................................................................................... 11
3.04.4 Safety Policy ................................................................................................................................. 12
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3.04.5 Order Acceptance Policy .............................................................................................................. 12


3.05 Orientation training (General rules & Regulation) .............................................................................. 12
3.05.1 Orientation Policy ......................................................................................................................... 12
3.05.2 Training and Development Policy ................................................................................................ 13
3.05.3 Probation and Confirmation Policy............................................................................................... 13
3.05 Departments ............................................................................................................................................ 14
3.05.1 Data Analysis Department ............................................................................................................ 14
3.05.2 Development Department ............................................................................................................. 14
3.05.03 Material Department ................................................................................................................... 15
3.05.4 Printing Department ...................................................................................................................... 15
3.05.5 Quality Control Department.......................................................................................................... 16
Chapter No:4

CONCLUSION ............................................................................................ 17

4.01 Strengths .............................................................................................................................................. 17


4.02 Weaknesses .......................................................................................................................................... 17
4.03 Opportunities........................................................................................................................................ 17
4.04 Threats.................................................................................................................................................. 17
4.05 Recommendations ................................................................................................................................ 18
Chapter No: 05 ................................................................................................................................................. 19

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

This section is about introduction of report. As a component of requirement of


Bachelor of Product & Industrial Design, internship is necessary for students. It includes
background, purpose, scope and objectives of the study.

1.01 Background of the study


Internship training program during Bachelor of Product & Industrial Design
Program is necessary for the partial fulfillment of the completion of Degree Bachelor of Product &
Industrial Design as per HEC (Hire education commission) requirement. It was necessary for me to
complete an internship period of about six weeks in any service or manufacturing concern relevant
to my area of interest and specialization. So, I chose the ME & CI department of manufacturing
firm because I am interested in this field and my study background is related to this field.

1.02 Purpose of Study


Internship is the capstone experience that provides internees with hands-on, realworld experience in a work setting. Ideally, internship enables internees to:

Use knowledge and skills got from the classroom,


Discover where further competence is needed,
Convert the bookish knowledge into practical life and
Become better acquainted with the types of work settings in which such Competence can be
applied.

1.03 Scope of Study


Scope of internship is that the internee will know some basic know how about the
business companies and their working environment at different seats and it will be helpful for them
in future.

1.04 Objectives of Study


The main objectives of studying at Forward Gear were:

To get work experience by working with a well-reputed organization.


To gain knowledge about the professional environment of the organization.
To know about the technology utilized by the organization.
To deal and manage with the situations of stress.
To implement theoretical knowledge in practical life.
To know firms activities i.e. its products and services.
To observe the finance system of the organization.
To know how this firm supports the economy of the country.

Chapter No: 02

OVERVIEW OF THE ORGANIZATION

2.01 Historical Background


2.01.01 Forward Group Pvt. Limited

In Sialkot 1990 Forward group has started its


working with the name of Forward sports. Forward Sports was
established by Mr. Khawaja Masood Akhtar, A young, ambitious
engineer, who had worked in the ball manufacturing for many years.
Mr. Masood had the idea of revolutionizing the hand-stitched industry
and with his innovation on team and his future\ prospective, he started
his new factory. The first years proved to be very difficult and many
hurdles had to be overcome. The competition in the industry was strong
and to break into these barriers seemed to be very difficult factory was
only one of the 5 or 6 suppliers for adidas and by far the smallest. So
the first year forward produced only an average of 1,000 balls per
month, only the low end price point balls, with a lead time of 120 days
made out of imported materials in the old traditional way of hand Figure 1 Khawaja Masood Akhter
stitched ball manufacturing. However, this was not what Mr. Masood
wanted. So as an entrepreneur, he started to try different things, while not forgetting his business.
He first found a local manufacturer for the ball materials.
He and Thai PU, a synthetic supplier from Thailand, which had a small plant in
Pakistan, developed their own material to be independent from imports and to have more and better
innovative choices. At the same time, a continuous and still ongoing process of improvement and
change in the factory started. Every operation step was questioned. Mr. Masood made numerous
trips to machine manufacturers all over the world, to see what was going on in the industries and to
implement this in his factory. In the meantime, he saw a continuous growth of his business by
delivering good quality products with shorter and shorter lead times. For Football 2006 Season,
Forward made about 4.7 million balls and had already become the second largest ball supplier.
From 2003, he modernized and changed the way of ball making completely. The lamination which
was done by hand in rather uncomfortable conditions was changed to machine lamination. In
Printing, 15 hand printing lines with rather high concentration of solvent were changed and
replaced by7 automatic, multicolor printing machines, with environment friendly conditions. The
cutting section, which used conventional swing - arm cutting machines, cutting 1 panel per time,
high power machines are now being used, which can cut up to 204 panels per stroke. Instead of
buying small batches of latex, Forward built 2 big containers for 250 tons storage with a centralized
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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.

Figure 2 Brazuca for Fifa-14


manufactured by Forward Sport

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.

2.02 Forward Gear Pvt. Ltd.


2.02.1 Introduction of Forward gear:

Forward Gear (Pvt.) Ltd. is a bag manufacturing


company targets to become the world leading bag producer by
providing quality, on-time delivery, cost saving, innovation and high
tech oriented solutions to the customers. With adidas as a main
customer, Salomon and Diadora are the brands that
Forward Gear is manufacturing bag items for. To meet the customers
requirement and to reach the objectives, the company will be operated
by the international standards and for making results-focused
management. The key competitors of forward gear are:
Starite ( China)
Long way (Vietnam)
Pungkook (Vietnam)

Figure 3 Forward Gear Logo

2.02.2 Business volume and number of employees:

As it is manufacturing firm its production depend on the quantity


of orders received but it has production capacity of 350,000 per month.
Figure 4 Forward Gear Building

Currently more than 1300 workers are working in organization.

2.03 Vision Statement


20 year of innovation - the past, the present and the future Forward Group Private
Limited is one of the few companies in
Sialkot industry that can trace its history back in 20 years. Forward is family owned manufacturing
and exporting business concern of footballs, volley balls, rugby balls, beech balls, and medicine
balls, shoulder bags, gym bags, team bags, shopper bags. The third generation of the family has
entered the field of international trade bringing together the established business and family values,
experience and skills coupled with pertinent business education, knowledge and expertise.

Chapter No:3

ORGANIZATIONAL STRUCTURE

3.01 PESTL Analysis


PESTL analysis stands for Political, Economic, Social, Technological and Legal
analysis that layouts a framework of macro-environmental factors used in the environmental
scanning component of strategic management. It is a part of the external analysis while conducting
a strategic analysis or executing market research, and gives a synopsis of the different macroenvironmental factors that the company must consider. PESTL analysis is a helpful imperative tool
for understanding the growth or decline in business position, potential and direction for business
operations in the market.
PESTL Analysis OF Forward Gear:

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

Specially designed department having capacity of 1000 bags per shift


with 15days of lead time and fulfill the requirements of small and quick
order needs of customers

3.02.3 Production Capacity

Forward Gear having capacity of 11,500 bags per day to fulfill the
requirements of heavy orders from the customers like Adidas.

Figure 5 Team Bag Prepared by FG

3.03 Employees Facilities


These following facilities are provided to employees,

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.

3.04 POLICIES AND ACHIEVMENTS


3.04.1 Social accountability policy

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:

Labor Law of Pakistan


Buyers Standard of Engagement
WFGI Code of Conduct
SA-8000 Requirements
ILO Convention

Figure 6 Laptop Bag of Adidas

3.04.2 Environment policy

Forward Gear (Pvt.) Ltd. is a company manufacturing & exporting bags


for international markets we understand that our business may have an environmental impact by
performing our activities and using raw materials, natural and artificial resources. Forward Gear is
committed to continuous improvement of its environmental management system for the
achievement of safe and conductive environment. We are highly concerned about the prevention of
pollution for the safe living. The Relevant NEQS of Pakistan WFSGI Regulation Related to
Environment Buyers Standard of Engagement to sustain this commitment, the requirements are
comprehensively mentioned in the document of the environment management system of ISO
14001.These apply to all related activities. This policy is documented, implemented, maintained
and communicated at all levels within the company and is available to public for their interest.

3.04.3 Quality Policy

Forward Gear (Pvt.) Ltd. Aims to maintain its leading position in bags

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industry by satisfying our respectable customers needs and expectations


through providing consistent quality products backed-up by:
Modern Research & Development Facilities

Lean Manufacturing
HSE/SOE Standard
OHSAS 18001 Standards
ISO-14001 Standards

SA-8000 Standards

Figure 7 Tennis Bag by Adidas

3.04.4 Safety Policy

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

3.04.5 Order Acceptance Policy

When orders come into a hand we will check the following things:

Estimates the order capacity


Check the material arrangement
Departmental capacity
Current capacity
Planning

3.05 Orientation training (General rules & Regulation)


Employees files maintained by account department. Employee is very much knowing about his
salary after joining the job.
3.05.1 Orientation Policy

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.

3.05.2 Development Department

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

Making the financial plans


Managing the payments
Managing the payroll
Record keeping
Reporting to managing director

3.05.03 Material Department

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:

Checking the stock


Order Placement
Maintaining Record of invoices
Issuance of material on MIR
Issuance of material on demand
Making daily, monthly and weekly reports of Material

3.05.4 Printing Department

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

3.05.5 Quality Control Department

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:

Having strong brands as it clients like Adidas and Reebok.


In Sialkot there is no other competitor of Forward Gear
It has huge production halls which can accommodate more than 1200workers.
Highly Qualified Management
High Security

4.02 Weaknesses
During my internship period I observed following strengths of the organization:

Internal employees politics effects quality of work


Loans are affecting profits of Forward Gear and also its goodwill.
Old employees are at more risk of their job termination.

4.03 Opportunities

During my internship period I observed following strengths of the organization:


Many market areas are untapped
Develop more portfolios in coming years

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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