1. Vision Technologies
Maximum Utilization of the Resources in Different Production areas of
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Football
Submitted By:
Ayesha Khalid (12121002) MBA Marketing
Iqra Kausar (12121001) MBA Marketing
Hassan Tariq (12121003) MBA Marketing
Haider dar (12121014) MBA Marketing
A project in partial fulfillment of the requirements
for the degree of Business Administration
Department of GIFT Business School
GIFT University, Gujranwala
2014

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Certificate
It is Certified that final project titled “Maximum Utilization of the Resources in Different
Production areas of Vision technologies” has be prepared by the students ,Ayesha Khalid
12121002, Iqra Kausar 12121001, Hassan Tariq 12121003 and Haider Islam dar 12121014
has been approved for submission.
Mr. Irfan Mehmood
Project Supervisor

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Declaration Form
We Ayesha Khalid 12121002, Iqra Kausar 12121001, Hassan Tariq 12121003 and Haider
Islam dar 12121014 hereby declare that Project titled “Maximum Utilization of the
Resources in Different Production areas of Vision technologies ” has been submitted by us in
partial fulfillment of the requirements for the degree of MBA and this project present carried out
at GIFT University Gujranwala campus and aims encouraging discussion and comments. The
observation and viewpoints expressed are the sole responsibility of the group members. It does
not necessarily represent position of the GIFT University Gujranwala Campus or its faculty. We
also understand that if evidence of plagiarism is found in our project at any stage, even after the
award of a degree, the work may be cancelled the degree revoked.
Printing Date: 13.4.2014
Ayesha Khalid
Iqra Kausar
Hassan Tariq
Haider Islam dar

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Department of GIFT Business School
Project Approval Sheet
Viva- Voce Examination
Title of Project: Maximum Utilization of the Resources in Different Production areas of Vision
technologies
Name of Students:
Ayesha Khalid (12121002) MBA Marketing
Iqra Kausar (12121001) MBA Marketing
Hassan Tariq (12121003) MBA Marketing
Haider dar (12121014) MBA Marketing
Approved By :
Mr. Irfan Mehmood
Supervisor
Mr. Abid Awan
Internal Examiner
Mr. Umar Mukhtar
Internal Examiner
Mr. Zikria Mian
Director Project
Mr. Asim Ilyas
Head of Department

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Dedication
We dedicate our project to our family and friends because without their prayers we would not be
able to accomplish this piece of work. We also dedicate this project to everyone including
respected faculty for GIFT University who supported us in different phases of the project.Special
dedication goes to Mr. Irfan Mehmood, Mr. Abid Awan, Mr. Umar Mukhtar and Mr. Jamil.

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List of Tables
Table Number & Heading Page No
Table 1 Division of labor 11
Table 2 Time Calculation For Each Activity 19
Table 3 Data for OEE Calculation 19
Table 4 OEE Calculation 20
List Of Figures
Figure Number & Heading Page No
Figure 1 Process Flow 8
Figure 2 GANTT Chart 13

7. Contents
1. Executive Summary .....................................................................................................................9
2. Acknowledgements ................................................................................................................... 10
3. Scope of project ........................................................................................................................ 11
4. Company .................................................................................................................................. 11
5. Vision Products ......................................................................................................................... 11
Footballs ...................................................................................................................................... 11
Handballs ..................................................................................................................................... 12
Futsal ........................................................................................................................................... 12
Special make ups .......................................................................................................................... 12
6. Process Flow Diagram ................................................................................................................ 13
7. Type of flow .............................................................................................................................. 14
8. Process Flow ............................................................................................................................. 14
Material Procurement ................................................................................................................... 14
Lamination ................................................................................................................................... 14
Cutting ......................................................................................................................................... 14
Printing ........................................................................................................................................ 14
Punching ...................................................................................................................................... 14
Sorting ......................................................................................................................................... 15
Stitching ....................................................................................................................................... 15
Quality Check ............................................................................................................................... 15
Bladder Inspection ........................................................................................................................ 15
Molding........................................................................................................................................ 15
9. Bottleneck ................................................................................................................................ 15
10. Labor utilization..................................................................................................................... 16
Division of Labor ........................................................................................................................... 16
11. Total Production .................................................................................................................... 16
12. Desired Production ................................................................................................................ 17
13. Capacity Utilization ................................................................................................................ 17
14. Process time.......................................................................................................................... 17
Throughput Time .......................................................................................................................... 17
Cycle Time .................................................................................................................................... 17
15. Process Flow for 12000 Footballs per day ................................................................................ 18
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8. Material Procurement ................................................................................................................... 18
Lamination ................................................................................................................................... 18
Cutting ......................................................................................................................................... 19
Printing ........................................................................................................................................ 19
Punching ...................................................................................................................................... 19
Sorting ......................................................................................................................................... 19
Stitching....................................................................................................................................... 19
Quality Check ............................................................................................................................... 19
Bladder Inspection ........................................................................................................................ 19
Molding........................................................................................................................................ 20
16. Recommendations ................................................................................................................. 20
17. Conclusion ............................................................................................................................ 21
18. Glossary ................................................................................................................................ 22
Calculation for cycle time .............................................................................................................. 22
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1. Executive Summary
This project is based on operations management. The basic purpose was to increase efficiency
and effectiveness of the entire system thus increasing productivity and to reach the goal of
making twelve thousand footballs in a day. We visited the production unit of Vision technologies
thoroughly to examine the overall processes involved in football making and identified the
bottleneck and defects if any in the system. After that we made a comprehensive process flow
chart identifying the different processes involved in production. Few processes were done on
machines while others were manually done. We identified that the flow was repetitive type of
flow which was following a proper sequence of steps. We identified the flaws in the process flow
Then we checked the time taken by each operation and identified the bottleneck. The problem
with the bottleneck was that all other operations were standardized but the printing section
involves use of different colors according to the order demanded. We also calculated the number
of workers used in each operation to check whether they are underemployed or over employed.
We identified that few process have optimum labor but few process involved excess labor and
few involved less labor. This would help in suggesting whether they should increase the labor
our decrease it thus maximizing utilization while minimizing cost. We also calculated the
capacity utilization by checking the present capacity and best operating level that they could
achieve. This suggests how much capacity they need to increase in meeting the desired targets.
We calculated the time required to complete each operation and come to know the throughput
and cycle time. We explained it with help of Gantt chart. After that we also applied the
improvement potential tool to suggest any improvements in the effectiveness of machines.This
was achieved by adding time required for each operation. This also helped in identifying the
bottleneck. After doing all the calculations and identifying the different processes we gave some
recommendations which would help in achieving the desired target of making 12000 footballs in
a day with optimum labor and machinery used so that overall cost would be less.

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2. Acknowledgements
This project would not have been possible without the support of ourParents, Sir
Irfanmehmood, Mr. Jamiland most ImportantlyAllah the Great gave us enough courage to
complete this project.
It is a pleasure to thank those who made this project possible. It is an honor for us to do this
interesting and valuable project because we have learnt a lot from the project and our practical
knowledge about operations.
We are indebted to our group fellows to support usthroughout this project. Our gratitude and
thanks go to everyone mentioned in the project.

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3. Scope of project
It is an operations management project and involves finding defects in the present process flow
production and how to increase their production using minimum labor and time. It would
increase their efficiency and effectiveness thereby increasing overall productivity. In this way
this project would be helpful in identifying the bottlenecks from the system and suggesting ways
and alternatives to the system for improvement and better functioning. By finding flaws in the
process flow we would be able to recommend changes to the process flow and this would help in
achieving the daily target of 12000 footballs. Mission Statement
4. Company
Incorporated as a private company in 2000, Vision technologies is located in Pasrur road Sialkot
Today VISION Technologies Corporation generates close to USD 1.3 million worth of business
every month. It seeks to become leading ethical manufacturer of athletic balls. It has an
international client’s from Europe, East Asia and North America.It ensures high quality, cost
efficiency and timely delivery.
Currently VISION employs around 300 workers in its different production and administrative
areas excluding stitching
"VISION Technologies Corporation seeks to become the leading ethical manufacturer of athletic
balls in the country, servicing an expanding base of satisfied, international clients.
VISION ensures high quality, cost efficiency and timely delivery, through professional
structures and innovative business processes, to extend its role as a model of corporate
responsibility.
5. Vision Products
The main product made by vision technologies is football which is exported all over the world
and is of FIFA quality best suited to players.
Footballs
Visions footballs are crafted to highest standards of performance.First they design each football
aroundtested concepts that guarantee stability, endurance and control in all playing conditions.

12. Like the all-time favorite 8-wing airblock bladder and high-abrasion surface treatment of poly-coat.
Then they add in cutting edge innovations that make sure you stay ahead in the game.
From now on all their footballs come with the PoP panel system and the VeT multi-layered
construction platform that gives you that ultra-smooth surface others only dream about.
Handballs
As the industry’s leading handball maker, VISION’s has learnt from the masters. Theirnew range
is designed to satisfy the world’s most experienced players. A revolutionary new microfiber
material forms the performance-enhancing platform for their 3rd generation handball. A unique
panel shape gives better grip and greater accuracy off the playing surface.
The super-soft casing is firm enough to respond to the finest technique. Combined with
trusted core componentslike the 8-wing airblock bladder and non-marking surface treatment, this
handball just can’t be beaten
Futsal
VISION is in the vanguard of the Futsal explosion with unique products designed in
collaboration with Europe’s leading designers.
With a finely calibrated bounce particularly tuned to high-abrasion indoor surfaces, their Futsal
is built around a reliable butyl core that helps shape retention and imparts flight accuracy within
the controlled movement necessary for the game.
The special high density poly-casing is further augmented by the resilient surface treated with
special color-coat. Their unique product translates the controlled passion of Futsal into
excitement like no other.
Special make ups
No other company is more equipped to respond to your special branding demands than VISION.
Our 25-years in the hand-stitched ball business are characterized by innovations that are now
industry norms. Whether it’s from-scratch development for the world’s leading brand or refining
excellence for heritage clubs infootball’s heartland, we’ve done it all.
We understand the game, the product, and your needs like no other company in Sialkot,
the global capital for hand-stitched balls. Bring us your ideas and we’ll make them work.
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13. Valid Quotation
Inquiries Launch to
vendors
Panel cutting
Cut panels readiness
notice
Sheets Readiness
notice
No
sticthinh=g
contracter Stitching process Initial Inspection
Material issuance
request for sticthing
Ball receipt from
contractor
No
Yes
Inspection Faulty Ball packing
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Process Flow Diagram
R & D (new product
Design)
Material inspection Material receipt
Material issuance
request from
lamination section
Random Inspection
Issuance kits sorting
Material receipt
From store
Payment receipt
from client
Selected Product
R & D (sample
production )
R & D (samples
dispatching to
prospective clients)
Work Order receipt
Raw materials and
component planning
Raw Material
stock Availability
Quotation entries
and generating
comparative
statement
Generation of
purchase order
Expediting plan and
monitoring
Laminating process
Lamination
readiness notice
Random Inspection
Ball issuance to
printing contracter
notice Random Inspection
Printing
Consumables
receipt
Printing process
Printing readiness
Kits sorting process
Issuance of kits to
OK
Washing and Final
Export
documentation
We have selected standard football which is having the greater demand. This football contains 8
wing air block bladder and high abrasion poly coat surface treatment. This is professional
category football exported to international clients.
Yes
No
Yes
Yes
No

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6. Type of flow
The flow here is repetitive process flow because there is some product variety but the volume is
high and products follow the same path with stable and predictable production volume. The lead
time and the set up time is short. The core of the manufacturing line stays the same and
specifications are changed for different products as needed. Repetitive manufacturing allows the
company to easily return to a prior product run if it needs to produce more to order.
7. Process Flow
Material Procurement
The material used in football making makes the football quality different. It can be made from
PVC sheets or fabric sheets. A total of almost 37 rolls are made per day which is further
laminated.
Lamination
It has 10 stations having 20 workers and 6 helpers so total of 26 labors are working here. 1000
sheets are laminated per day. 2 heating rooms are utilized. 1 heating room has capacity of drying
400 sheets per day. Almost 6.6 balls can be made from single sheet. It is a three day process.
Cutting
Cutting is done with the help of machines. They are utilizing 13 machines for cutting the
laminated sheets. 75 sheets could be cut by a single machine. 19 persons are working with these
machines. 6 persons have the responsibility of sorting out the pieces.
Printing
Printing area has 70 stations as 2 to 3 type color printing done on average. In this way almost
8000 footballs are printed per day.
Punching
There are 11 punching machines. 1000 to 1200 footballs could be punched by single machine.

15. Sorting
Sorting area has 7 stations out of which 5 stations are for sorting the football pieces and 2
involve bladder pasting.
Stitching
Stitching is done by outsourcing. They are almost 500 suppliers. Demand for hand stitched
footballs are more so it is done in stitching centers. Quality checks are also done by visiting the
centers.
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Quality Check
There is 24 hour hold and can be checked any time at any department.
Bladder Inspection
It is done in 2 sets. First set involve 7 persons and check 4000 bladders per day. The second set
involves 5 persons checking 2500 bladders per day.
Molding
They have 26 molding machines. Molding is necessary so that there is no difference seen in
quality and shape of footballs and all footballs look alike as they are hand stitched. Almost 8
persons work here and mold 450 balls per person.
8. Bottleneck
The printing process takes the larger time so it is bottleneck in the system. There are other
processes which took more time but they could not be considered as bottlenecks because they
were held without use of labor and machines. The problem with the printing process is the
variation of designs and different colors demanded. This also causes the production to seize at
various points and overall production is less depending on order.

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9. Labor utilization
Labor works on the numbers of hours worked and get wages for their work.Total labor involved
in production is 307 which are distributed among different areas of their expertise as shown in
the figure below:
Division of Labor
Packing 19
Materials Procurement 23
Panel Sorting 29
Bladder Inspection 18
Panel Punching 37
Delivery and Receive 6
First Inspection 35
Quality assurance 64
Washing 32
Lamination 26
Balls repair 5
Follow up 10
Bladder Pasting 9
Warehouse and Logistics 8
Balls Molding 9
Out of these process we have highlighted those processes where there is over employed labor.
Other processes have labor at optimum level.
10. Total Production
The company is now working 8 hours a day and the production for a day is 6000 footballs. This
production varies sometimes depending upon the type of order also.

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11. Desired Production
Company wanted to double its daily production from 6000 to 12000 footballs which is dependent
on different processes involved in the production Unit. So changes are required in the process
flow to achieve this target.
12. Capacity Utilization
Capacity utilization rate reveals how close a firm is to its best operating level and can be
expressed as
Capacity utilization ₌ Capacity used/ Best Operating Level
≈ 6000/ 12000 ≈ 0.5 or 50 %
It means that plant is currently running at 50 % capacity. So we have to suggest ways in meeting
the best operating level with efficiency plus effectiveness.
13. Process time
Throughput Time
By adding time of different processes we get the manufacturing lead time or through put time
which is equal to 14 minutes for the first football.
Cycle Time
The time for each successive unit of football is 3 min 40 seconds
14. Gantt Chart
A Gantt chart, commonly used in project management, is one of the most popular and useful
ways of showing activities (tasks or events) displayed against time.

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250
245
212
210
200
467
437
397
813
2
10
5
33
30
Ball packing
washing and final…
Checking & molding
Stitching
Punching
Material Sorting
Printing
Sorting Cut pieces
Cutting
Bladder pasting
Oven heating
Bladder Inspection
lamination
15. Process Flow for 12000 Footballs per day
Material Procurement
There are two stations for the material inspection but only one station is used. They can use both
the stations to complete the demand for the production of 12000
Lamination
The Lamination department has 15 stations out of which 10 stations are working. A total of 1200
sheets are made from which almost 7000 footballs can be made. If they utilize the remaining
stations then the target of 12000 footballs can be achieved here. Now oven is used for 8 hours but
it can be used overnight. This will double production to 12000.
One station production per day =120 sheets per day
15 stations will produce = 120*15 = 1800 sheets per day
1 sheet = 6.6 footballs
0
150
391
527
808
120
30
50
141
6
40
60
281
5
0 200 400 600 800 1000 1200
Material Procurement
total time
time per activity

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1800 sheets = 1800*6.6 = 11880 footballs per day ≈ 12000 per day
Cutting
The cutting section has 13 machines. They are utilizing full capacity here by making 75 sheets
per machine so a total of 975 sheets are made per day. They need to install 11 more machines to
reach target of 1800 sheets per day and 12000 footballs per day.
Printing
Printing process is a bottleneck because it involves different orders with different demands of
colors and designs. They will have to recruit more labor in order to meet the production
recruitment.
Punching
In the punching section the labor is more and has workers with them. It has 22 machines out of
which 11 machines are working and these are enough to make 12000 footballs per day. They can
reduce labor here to reduce some cost.
Sorting
Sorting area has 7 stations out of which 5 stations are for sorting the football pieces and 2
involve bladder pasting. 10 stations more will fulfill the demand for the 12000 per day.
Stitching
Stitching is done by outsourcing. New suppliers will be needed.
Quality Check
There is 24 hour hold and can be checked any time at any department.
Bladder Inspection
There are two stations one giving the production of almost 4000 bladder checks per day. They
need to install one more station which will give them production of 12000.

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Molding
They have 26 molding machines. Molding is necessary so that there is no difference seen in
quality and shape of footballs and all footballs look alike as they are hand stitched. Almost 8
persons work here and mold 450 balls per person.
16. Improvement Potential Tool
We have used Overall Equipment Effectiveness because it is a universally accepted method for
measuring the improvement potential of a production process.
OEE takes into account all losses (Down Time Loss, Speed Loss, and Quality Loss), resulting in
a measure of truly productive manufacturing time.
It is based on three factors which include availability, performance and quality.
OEE = Availability x Performance x Quality
OEE = 73.41 %
So there is improvement potential of further 27 %
Overall Equipment Effectiveness measures how close we are to perfect production
(manufacturing only good parts, as fast as possible, with no down time). Monitoring our OEE
score on its own is not all that helpful to improving production. The true value of OEE comes
from understanding the underlying losses: Availability Loss, Performance Loss, and Quality
Loss. By focusing on these losses, and more importantly, by taking action to reduce these losses,
our OEE score will naturally improve.
17. Recommendations
 As printing is the bottleneck here so they should consider using machine printing for
whole sheet.
 Machine printing will be helpful in printing whole sheet then they will use automatic
cutting machine for whole sheet. This will increase their production, reduce the labor cost
and bottleneck time will be reduced.

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18. Conclusion
We can conclude that the goal of 12000 footballs can be achieved if certain changes in the
process flow can be done. We can also say that operations management is helpful in increasing
the productivity of the system. Furthermore increasing or decreasing the number of workers at
the appropriate places would be helpful in maximizing utilization of resources. Managing
operations help in reaching the desired targets by use of tools like OEE, etc

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19. Glossary
Calculation for cycle time
Lamination
A single sheet time ₌ 3 min 21 sec
Total time in seconds₌ 201seconds
Footballs made from a single sheet₌ 6.6
So 1 football timing ₌201 sec/ 6.6 ₌30 sec
Drying Sheets
1 heater dries 400 sheets per day
So total footballs make from single sheet = 6.6
So football material dried by 1 heater = 6.6 * 400 =2640
So 3 heaters can dry footballs = 7920
Time for drying sheet takes = 5 sec
Bladder Checking
Checking one bladder require ₌ 1 min 50 sec
Deflating time ₌ 1min
Cutting
Cutting single sheet ₌3 min 35 sec
Total time in sec ₌215 sec/ 6.6 ₌ 33 sec
Material Sorting
A single ball sorting material takes 6 sec.

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Printing
Printing process is complicated and there is time variation depending on order but generally there
is 2 to 3 color scheme order for a particular football.
Painting 16 pieces in football requires time₌ 47 sec
If 3 colors involved then total time ₌47*3 ₌ 141 sec
So time in minutes₌2 min 21 sec
Punching
There are 16 pieces to be punched together for a single football and these pieces require time ₌
40 sec.
Back Receiving
The balls after being stitched are racked together. A single rack can hold up to 100 balls. One
rack is filled ₌ 4 to 5 min
Time for one ball ₌0.41 sec
Holding
These balls are kept in racks for 24 hours to assure that there is no air leakage.
Washing
Process of washing has some series of steps like in a conveyer belt. Overall time for 1st football
is 4 min 41 sec. After that next football is cleaned every second.
Quality Check
It takes 1 min to check whether football is faulty or of low class.
Average faulty footballs are 2% in 100 racks so 10 footballs are mostly faulty.
Faulty football requires 40 sec of 1 ball, deflating and packing

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Packing
Packing single ball requires 5sec
Time Calculation for Each Activity
Data for OEE Calculation
Item Data
Shift Total Length 540 Minutes
Meal Break 60 minutes
Downtime 40 minutes
Ideal Run rate 17 pieces per minute
Total Pieces 6000
Reject Pieces 10
Activity
Total Time
(sec)
Time per activity
(sec)
Material Procurement 0 120
lamination 150 30
Bladder Inspection 200 50
Oven heating 210 10
Bladder pasting 212 2
Cutting 245 33
Sorting Cut pieces 250 5
Printing 391 141
Material Sorting 397 6
Punching 437 40
Stitching 467 30
Checking & molding 527 60
washing and final inspection 808 281
Ball packing 813 5
Through put time 13.55
≈ 14 min

25. Planned production Time Shift length- Breaks 480
Operating Time Planned production time- downtime 440
Good Pieces Total Pieces-reject pieces 5990
Availability Operating time / Planned production time 0.916667
Performace (Total Pieces/operating time)/ideal run rate 0.802139
Quality Good pieces/ total pieces 0.998333
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