THE GENERAL TYRE AND RUBBER COMPANY OF PAKISTAN.

CONTENTCONTENT

• 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

Chief Financial Officer

Divisional Manager Finance

General Manager

Cooperate Services

General Manager Works

Divisional Manager Sales

RM

Divisional Manager Sales

OE/CS

Executive Director Marketing

Head of Internal Audit

Divisional Manager Central

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

0.00

500,000.00

1,000,000.00

1,500,000.00

2,000,000.00

2,500,000.00

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 - KARACHIADAM 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 KHANAL-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 - KARACHIDELTA INNOVATIONS LTD - KARACHI

STAR TRUCK 640-13 10PR

DEWAN FAROOQ MOTORS LTD - KARACHIDEWAN FAROOQ MOTORS LTD - KARACHI

SANTRO PLUS 1000 CC 155/70R13

HYUNDAI SHEHZORE 650-14 10PR

GHANDHARA INDUSTRIES LTD - KARACHIGHANDHARA INDUSTRIES LTD - KARACHI

ISUZU LIGHT TRUCK 750-16 14PR

ISUZU TRUCK / BUSES 900-20 14PR

GHANDHARA NISSAN DIESEL LTD - KARACHIGHANDHARA NISSAN DIESEL LTD - KARACHI

NISSAN TRUCKS / BUSES 900-20 14PR / 1100 - 20 16PR

G.M. UNIVERSAL TRACTOR LTD - KARACHIG.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 - KARACHIHINOPAK 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 - LAHOREHONDA 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 - KARACHIINDUS 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 - LAHOREMILLAT 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 - KARACHIMASTER MOTOR CORPORATION LTD - KARACHI

MASTER FOTON 650-16 10PR

MASTER YUEJIN 750-16 14PR

PAK SUZUKI MOTOR CO. LTD - KARACHIPAK 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 - KARACHISIND ENGINEERING LTD - KARACHI

DONG FENG 650-16 10PR

DONG FENG 750-16 14PR

SIGMA MOTORSSIGMA MOTORS

DEFENDER 750 R 16 10PR

DEVELOPMENT PROCESS

1. ANNOUNCEMENT OF PROJECT LEADER AND TEAM.

2. DESIGN INPUTa) PRODUCT REQUIREMENT FROM OEMb) TYRE DEVELOPMENT CHECK REQUEST

SHEET FROM OEMc) PATTERN SELECTION BY OEMd) TYRE CONDITION EQUIPMENT VALUESe) 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

MIXING CALENDERINGFABRIC

CUTTING

BANDBUILDING

TYREBUILDING

VULCANIZINGTYRE

INSPECTION

EXTRUSION

BEADBUILDING

Purchase Raw Materials From Conti Approved Suppliers

Store in RMWH

Finished Goods Ware House

Testing/Certification QA-LAB

Reliability Testing

Uniformity Evaluation/Grading

QUALITY ASSURANCEQA. 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.

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

QUALITY ASSURANCETESTING FACILITY FOR RAW MATERIALS

(QUALITY ASSURANCE LAB.)

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 CARBONPELLET HARDNESS TESTER HARDNESS OF CARBON BLACKS.

EQUIPMENT:EQUIPMENT: TO EVALUATE:TO EVALUATE:

QUALITY ASSURANCE

TESTING FACILITY FOR END PRODUCT

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

EQUIPMENT:EQUIPMENT: PURPOSE:PURPOSE:

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 and Quality ControlSYMBOLS USED FOR IDENTIFICATION

= Q.A. INPROCESS AUDIT= LAB TETSING (100%)= STATISTICAL PROCESS CONTROL= TOOL & GAUGE CONTROL PROGRAM= OPERATOR AUDIT= PULLEY WHEEL TESTING= 100% INSPECTION= SURVEY= TRACEABILITY= 2ND INSPECTION BY Q.A= AIR RETENTION TEST

CEMENTHOUSE

BEAD FORMINGPREPARATION

RMWHINCOMING RAW

MATERIAL4 ROLL

CALENDERSTOCK RADIAL TIRE TIRE RADIAL TIRE FINAL

PREPARATION BUILDING LUBRICATION CURING FINISH

STEELASTIC

BULGE/INDENT. TIRE DYNAMICUNIT UNIFORMITY BALANCING

OPTIMIZERTRIPLEX

MIXING EXTRUDER2ND

INSPECTIONBY Q.A.

3 ROLLCALENDER

FINISHEDGOOD

WARE HOUSE

Manufacturing process & Quality Control at Proto & Mass Production Scale

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