History

Sonica Plastic industries started its business with the name of Haji Munawar and brothers in
1980 by manufacturing spare parts of Plastic washing machines on a small scale under the
supervision of Muhammad Munawar. Factory was located at Sialkot Road Gujranwala.
In 2000 this business registered its name as Sonica Private Limited and expand its business.
continuously and gradually this small unit started manufacturing of Plastic Furniture on a large
scale. In 2009 Sonica Private limited its own automatic machinery have more than 80,000 units’
production capacity per month. Sonica has its own die shop where we have the capacity to make
our moulds avoiding unnecessary delay and meeting our quality standards. Washers, Dryers,
Tables moulds wear made in our own shop. this is all achieved by sharing committed
management and experienced employees.
Sonica Private Limited satisfying hundreds of million customer all over Pakistan and abroad too.
Today, as we are witnessing a new era of industrial, economic and commercial advancement, we
have developed all our efforts for the development. In search of excellence, we have invested in
the complete training of our engineers and setup state-of-the-art equipment and now specialize in
service and maintenance of varied Parts of Plastic Furniture. The concluded aspect of our
diversified services is our quality application to achieve the standards set forth by the demands of
time and development. Hence, we are committed and dedicated at all times to be the best at what
we do for our customers and their permanent satisfaction.

Introduction

The whole success of this firm is due to the mercy and benevolence of that supreme power which
controls our life and death, and gives us the utmost respect in this world. Then it is due to the
long and untiring efforts of the supervisors, designers and our labor which given this firm an
recognition. Sonica is an industrious enthusiastic and quality conscious Company which is
known for producing quality plastic furniture. Our products represent the taste and trends of the
modern times. Each and every piece is examined carefully by the Quality Control Staff before it
leaves to ware-house. Research and Development Section endeavors day in and day out to create
new designs and achieves even better standards. Our efforts are destined towards bringing new
comforts in your life style and more beauty in your home.
Sonica Plastic Industry is a premier plastic moulds company in Pakistan. Quality, economy, and
style are the hallmarks of Sonica., Sonica has been engaged in producing plastic products for
home office and washing machine industry use that enhance elegance, style, and luxury of your
place.
Our products offer a wide range of designs, colors, and sizes, conforming to high quality
standards of durability and aesthetic values. The Company has a national coverage of dealer,
merchants, and retailers to ensure efficient and fast delivery
Vision
Constantly improving the skills of organization’s members to become the market leader in every
of our product
Mission
To continue to distinguish ourselves as the premier source for manufacturing high quality
products and the very best professional service

Hierarchy of Sonica Company

Sonica PVT limited is fully centralize company its Management hierarchy is mention below

Chairman : Haji
Munawar

Managing
CEO: Mr. Naeem
Direceter : Mr.
Mughal
Salman

Accounts
Plant Manager : HR Manager : Mr Sale Manager : Mr
Manager: Mr.
Mr. Zain Asif Ali Ahmad Muhammad Awais
Muhammad Umair
Method used for Maintenance of equipment
There are two methods for the maintenance of the equipment or machinery these methods are
mention below
1) Break down Method 2) Preventive Method

Break down
In break, down the machine will be shut down for some period of time. in Sonica the molding
machine will be shut down if the problem of software will arise. if software problem will occur
then first of all we find that where the problem will occur for example find the place where the
problem will have and then we solve the problem of the software. in Sonica PVT LTD the
department of software was held and some engineer will have held by the Sonica, who have done
the software engineering from the highly qualified universities. they will find the problem that
some time the moulding machine will not work properly like the engineer will give some
instruction to the machine that at such time the machine will complete the body of the washing
machine. if the machine will give the final product at less or more time then he finds the problem
that why machine will give before or after time. then the engineer will find the problem like the
machine will give some repetition. then the software engineer will solve the problem. it will take
round about 10 to 15 days for the maintenance. there is no alternative for that in the Sonica PVT
LTD. all the production will stop and there is no alternative for that. all the suppliers will not
receive the final product. the company will face the crisis like the demand for that the product
will arise and the company will manage the inventory for the supplier. some other problem like
the complete software will shut down. this is the critical situation that the engineer will face. in
this scenario the engineer will not know where the actual problem was occurred. this will take
some time for example the engineer will find the place the affected place of the moulding
machine then after that the engineer will solve the problem of the machine. this category will fall
in the break down method.

another problem that will occur in the machine is that the screw warm was not work properly. the
function of screw in the machine is that its move the machine smoothly and removes all the spot
on the body of the machine body. if the screw warm was not work properly then the spot will
occur on the surface of the machine body. its take almost round about 10 days for the
maintenance, however it’s also available as new but it is very expensive and the Sonica PVT
LTD does not afford the new screw warm. the screw warm was maintaining but after some time
it was replaced by the new screw warm. because if we maintain it after some repetition it was not
work properly. the company was replacing it after some period of time. Another problem that
will fall in the category of break down is that its jack was not work properly the machine was not
move properly, like the machine will not move according to the given instruction. the function of
the jack is that the machine will move forward or backward. the machine will move because if
according to the order the die casting will change and according to the die casting the machine
will move according to the die of the machine. The jack will also take the 10 days for its
maintenance because it has high wait and all the machine will shut down because if the jack was
not work then the die was also not fit to it and the work was not done according to the given
order. that’s why the jack was also fall in the category of break down.

Preventive Maintenance Method

In the preventive method the shutdown of machine will short like if any spare part of the
machine will not work then it was replaced by new or it maintain quickly like the production will
not stop or any type of production will not have affected by the failure of any spare part. there
are many spare parts that will fall in the category of preventive method. the seal of the machine
was leak due to its frequent usage, there is no check and balance of seal checkup in the Sonica
PVT LTD. the will notice at the time of leakage and not take precaution before the time. the seal
was replaced by the new at some period of time like it will take some hours to replace it. the
company will hold some seal will was commonly leak then at the time of leakage it was replaced
the seal quickly. but at the standard the seal was checked after some period of time or at the time
the machine will work, like there are standard hours at which the seal was replaced. but in
Pakistan there is not any company who was follow the standard. another problem that will
arrived in the machine is that the oil was not changed according to the given time or according to
the standard hours. the worker or foreman will come at the morning and check the oil if it was
according to the gage then it will start the machine if it was not according to the given gage then
it will complete it according to the given standard. at this scenario the machine life was reduced
because the oil was not changed by the given time and the black oil was reduced the life of the
machine

another method that will fall in the category of preventive method is pump that will change after
some period of time. its pump was not change because the maintenance was not done according
to the standard. the Sonica PVT LTD was changed it pump when the machine was shut down and
the whole production was stop. the pump was changed by the maintenance department
approximately in 2 to 3 hours. another problem that will occur is the wall that will change after 2
months but the Sonica PVT LTD was change it after 3 months. the function of wall in the
machine is he puts the material to the next pot that is the boiling point of the machine. when the
material is put in the machine the wall is shift the whole material to the boiling point. another
problem that will fall in the category of preventive is that its die casting that will moulds the
whole material into the specific shape. the problem that will occur is that some spot was occurred
on the final product and some black spots was present on the surface. the employee will buff the
die on regular basis and also polish the die on the daily basis. this will all the problem that will
fall in the category of preventive method.

Recommendation
the recommendation that I will give to the Sonica PVT LTD is that first of all in the category of
break down. the company must should have the alternative of break down, if the machine was
stop and not work then the whole production was stop and all the order that he will received is on
pending position. he checked the software on the weekly basis that if any problem was occurred
in the machine then he will check it and solve all the problem. if the engineer will do that then
the company will not receive their pending order and the whole production was not stop. another
problem is that jack. he gives oil to the jack on the regular basis because if the jack was received
oil the he works smoothly and its life was increased at the given period of time. If the company
was do this then the whole production was not stop and the company was not face the shortage.

the recommendation that i will give to the category of preemptive method is that he check the
seal after 2 to 3 weeks because the seal was leaked when we not check the machine spare parts
according to some period of time. another reason is that when we put the more oil into the
machine the excess of oil in the machine is the reason of leakage of seal. when we not check the
oil on the regular basis. when the oil was decrease according to the gage then the machine was
also stop and not work properly. the company employees regular check the pump. if the pump
was not work properly then the production was also stop. we check the pump also on regular
basis, because the company location was there where the dust was a lot of dust. the dust
intercepts the pump to work according to the standard. so we check it on regular basis. at the end
there was a problem that is die casting. when the dust was on the die then the spot was occurred
on the final product. we check the die on the regular basis and polish the die and also give some
buff on the die then it will work properly. so the company should check it on regular basis.