Al Fayha Aluminium Factory L.L.C.


AFAP - Al Fayha Aluminium | AFF - Al Fayha Fabrication | AFG - Al Fayha Glazing
AFSP - Al Fayha Small Projects

Selection of Different Glass Types | Safety Procedures | Manufacturing & On Site Services
Environmental Care
| Human Resource Managment |
Extracurricular Activities | Method Statement


AFAP – Al Fayha Aluminium Project:      

Aluminium curtain walls and structural silicone glazing through joint venture with Sepalumic , France.

  • 4-way.

  • 2-way.

  • Unitized.

  • Semi unitized.


AFF – Al Fayha Fabrication:

  • Doors: Sliding, hinged, frameless, automatic, and gates.

  • Windows: Sliding, hinged, ventilators, tilted, and turn & tilt systems, tilt & slide systems, fixed.

  • Railings: Staircase and balcony.

  • Shop fronts, facades, and partitions.

  • Rolling shutters, louvers, and grills.

  • Skylights.

  • Cast and welding aluminium.

  • Double colored/wood colored aluminium.

  • Interior real wood / exterior aluminium profile.


AFG – Al Fayha Glazing:

Double-glazing units are encouraged on all glass units to decrease energy consumption to create a more quiet and comfortable atmosphere and a healthier and cleaner environment.


AFSP – Al Fayha Small Projects:

Unlike other companies we not only target the large projects that are available. We have created a team that oversees small projects. Such projects can vary from one complete villa all the way to a kitchen backdoor. This department is managed by the same team for the larger projects but taking into consideration limitations to budget, time delivery, and the final personal touches.


Selection of Different Glass Types

The type of glass and color is one of the most difficult decisions to be made in a building structure since there is a wide variety of types and colors. Even though some types of glass are restricted to specific colors, to make this process quicker and more efficient for our clients we suggest that a meeting is held with us during selection. If the client is not convinced of the quality or the performance of the glass, we are always more than willing to arrange a meeting with the supplier. Since the list of colors and performance are endless, only a few basic descriptions of the types of glass are mentioned below.

 

Tempered Glass:

There are two types of tempered glass, “Heat Strength” and “Toughened.” In both cases the glass panel, after being cut, is inserted into a high temperature oven to be processed. Toughened glass becomes four times as stiff as regular glass. And a “wavy” effect is caused. Heat strength glass is only twice as solid as regular glass, but it maintains its flatness unlike the toughened glass. Tempered glass is also called security glass since it is less likely to break, and even if it happens to break, it shatters into small pieces to avoid injure to anyone.

 

Laminated Glass:

Laminated glass is manufactured by inserting a nylon film between two tempered glass panels. It is then inserted into an oven at a high temperature to melt the nylon film, and a vacuum effect is created where all the air is sucked from between the panels, causing them stick together and appear as one panel.

The film that is placed between the two glass panels is called PVB, and it is available in several shades of colors or clear. The thicker the glass the more PVB films are required, and the more PVB films are used the stronger the glass becomes.

Laminated glass is used as a safety precaution, because once smashed the glass stays intact and in its place. Laminated glass is most commonly used for balconies and public areas.

 

Wire Glass:

This glass is relatively expensive and is most commonly used in bathrooms, kitchens, etc. The wire inside the glass is similarly processed as the PVB in laminated glass, therefore giving it similar features. The glass used may be clear or obscured depending on the client’s preference.

 

Sandblasting:

Sandblasting can be usually done to any type of glass, and in the case of tempering, the sandblasting is done first. There are two types of sandblasting, regular and aluminium oxide. Regular sandblasting does not give a constant surface, unlike the aluminium oxide. Glass can have any pattern or design (such as company logo) sandblasted for a more corporate look, a simple interior decorative touch. To make the sandblasting even a greater feature, a polymar coating can be added which allows the glass to not leave any fingerprints or dirt when touched.


Safety Procedures:

At AFAF we take into consideration not only the interest of our clients and suppliers, but our employees. AFAF uses equipment of the highest standards in safety whereby all our employees at sites and production plant are highly equipped.

It is also our policy to make sure that all types of safety equipment are available for our employees’ safety, such as the use of straps while using cradles or exterior work. The use of earplugs while operating high-noise machinery is a requirement at the production plant as well as protection masks supplied for work and welding machines. First-aid gear is always provided at project sites at a central location with the main contractor, our manufacturing plant is also installed with several first-aid kits. These are just a few steps we take into securing the health and safety of our employees. All our employees at the production plant are trained to use the equipment properly. The following is a summarized list of items or procedures used as safety measures at AFAF.

  • Protective wear

  • Shoes

  • Helmets

  • Goggles

  • Fire extinguishers

  • Earplugs

  • Training on the use of equipment

  • Cradles

  • Straps

  • Gloves

  • First-aid kits

  • Regular checks on service, equipment and electrical layout.

Control System:

The technological advances that have taken place in the recent years, have allowed AFAF to take on larger projects. In many cases we have been able to lead the competition through our efficient management. The management of projects is controlled through several custom made systems to suit our needs. The following is a list of systems that are used:

 

  • TDD – Technical Design Department:

TDD, being one of the most important facilities offered by Al Fayha Aluminium Factory, allows us to offer our clients a service rarely provided by our competition. This facility is automatically implemented on all approved projects and it is a beneficial service for the client since it provides the following:

Reducing Costs  Enhancing Design     Visual and Technical Options

 

  • OTS – Order Tracking System:

This system starts at the very beginning of a project, even before the contract has been signed. The drawings are studied by a team of engineers who are specialized in calculating the estimated cost of a project, which is known as our C.E.D. (Cost Estimation Department). Knowing the quantities that are needed, several suppliers are contacted for all items to be quoted on prices and delivery time. When that information has been received it is entered into our system, and a report is created detailing the price, quantity, and the feasibility of the project by the deadline date.

  • AACA – Accurate Accounting Cost Analysis:

This system was created for several reasons, since its output results in vital information that leads to a better management. The results are given only after the completion of the project; which are as follows:

  • It compares the estimated cost with the actual cost in detail for each and every project.

  • Delivery time and actual deadlines are compared, any delay is noted and the results for that delay. Results for delay include reasons such as late arrival of supplies or other subcontractors were delayed.

  • Net profit for the projects.

  • Total cost.

  • Suppliers used for the project, and their performance in comparison to others.

  • It also compares the profit rate of this project with previous projects from the same and other clients.

Most companies similar to ours have found this system of extreme importance but have had difficulties in the implementation process. Though with the help of our well trained motivated employees, and our hard-working efficient management team we were able to ease the implementation.


Manufacturing & On Site Service

AFAF’s manufacturing plant is equipped with the latest machinery, which are staffed by trained employees. The manufacturing manager supervises the manufacturing processes and workflow according to a chart of deadlines given by the project manager. All products that are manufactured are checked by two different teams for any adjustments necessary before they are sent to the site. The manufacturing manager leads one team, and the other team is led by the quality assurance manager who also checks for the final adjustments required at the sites after installation has taken place.

 

Curtain Wall Specialist:

Sepalumic curtain wall systems are the result of commitment and extensive research, development, and expenditure from both parties. The Sepalumic systems have been developed to overcome various down falls found in other systems.

Some of the main features include efficient drainage, thermal efficiency, ventilation, tolerances, and high levels of acoustic insulation. By means of concealed drainage channel within the glazing rebate, and by offsetting horizontal and vertical components, water and condensation are directed from horizontal components into the vertical by the “waterfall” principle. The mechanical joining system eliminates sealing faults in critical corner positions, creating the effective drainage downwards through the system. The curtain wall systems are available in a variety of component widths, offering a wide range of external façade designs.

Structural & Double Glazing:

The structural glazing system eliminates horizontal and vertical external framing of the facades, thereby allowing architects to design monolithic facades without interruption. AFAF manufactures double glazed units according to European and American standards.


Environmental Care:

Environmental Care is also a core value of AFAF – a value reflected in how we develop our products, how we act in society, and how we deal with our customers and employees.

Human Resource Management at Al Fayha Aluminium Factory:

 

AFAF’s HR Department plays a fundamental role in allowing us to present our services to you. We have made sure that the HR division’s employees have certain capabilities such as mastery in the business industry they are working in, human resources management, change, and personal credibility. The following are a list of the HR Department’s activities:


Human Resource Management:

  • Planning

  • Recruitment

  • Staffing

  • Job Design

  • Training and development

  • Performance appraisal

  • Communications

  • Compensation and benefits

  • Labor relations

 

Some detailed activities are listed below:

  • Advice and counsel: The HR Department often serves as an in-house consultant to supervisors, managers, and executives. Given the knowledge of internal employment issues (policies, labor agreements, past practices, and the needs of the employees) as well as the external trends (economic and employment data, legal issues, etc.)

  • Service: The HR Department also attends to activities such as recruiting, selecting, testing, planning, conducting training programs, and hearing employees concerns and complaints.

  • Policy Formulation and Implementation: The HR Department at AFAF proposes and drafts new policies or policy revisions to cover recurring or prevent anticipated problems. These are proposed to the senior executives of the organization, who review and declare judgment on the policies.

  • Employee Advocacy: One important factor we pride ourselves at AFAF is that the HR Department listens to the employee’s concerns and represents them to the senior managers. This trend has allowed for minimal disturbances whether external or internal change is occurring.

The following is a list of the employees concern that we take into consideration when making or changing policy on internal issues.

 

Employee Concerns:

  • Diversity of backgrounds

  • Age distribution

  • Gender issues

  • Education levels

  • Employee rights 

  • Privacy issues

  • Attitudes toward work

  • Family concerns

 

AFAF has always taken into consideration the changes of the makeup and expectations of employees. Factors such as age, gender, race, and education have always been taken into consideration for every employee regarding working hours, salaries, holidays, benefits, bonuses, housing, etc. Also with time and experience, AFAF has taken into consideration the inflation and the time period employees have been with the organization.

At AFAF we make sure that the employees’ civil rights are given the utmost respect. This was accomplished, by giving the employees more than the law requirements, which allowed us to compete with multinational organizations on an international standard. We take pride in saying that our employees are the best paid and morally satisfied in the industry.

In recent years, the educational attainment of the U.A.E. labor force has risen dramatically. Therefore we have also increased our employees’ minimum requirements and educational levels, to give a better service to the client and to be able to give back to the community, which we have prospered from.

Competitive Challenges:

  • Globalization

  • Technology

  • Change management

  • Development of human capital

  • Market responsiveness

  • Cost containment

Competitive Challenges: Globalization

In order to grow and prosper, AFAF seeks business opportunities in global markets since it was first established. AFAF has learnt the value of, competition and cooperation with foreign companies since they have become increasingly important focal points for business.

By partnering with firms all over the world and using current technologies, we offer our customers “anything, anytime, anywhere” policy. Since it was our decision to go global, we had to take the initiative to balance issues related to different geographies, cultures, laws, and business practices. These factors are also included in our human resource policies.

Competitive Challenges: Technology

Advancements in computer technology have enabled us to take advantage of the information explosion. With computer networks, unlimited amounts of data are stored, retrieved, and used in a wide variety of ways by our entire staff.

A few examples of how we took advantage are the following:

  • Our sales department knows the required target outstanding from the accounts department.

  • The project management department can check current balance of every project’s budget.

  • The project management department can check on the estimation made by the estimation department for every project on hand.

  • The purchasing department can check and review what items are necessary to be purchased for all projects, also new items available globally.

 

The above mentioned points help departments to not only attain their targets, but also to surpass. Information technology has also changed the management of our human resources entirely. We have created a human resources information system where by we have a current and accurate data on all our employees. This system helps our human resource management department make decisions in regards to the strategic planning of the organization by forecasting promotions, compensation, benefits, bonuses, etc.

 

Competitive Challenges: Managing Change

Since technology and globalization are only two factors that are keeping us market leaders, managing change is another force in our organization that is keeping us at the top. We have invested time and money into creating programs at AFAF such as total quality, continuous improvement, downsizing, reengineering, outsourcing, etc.

We have come to an understanding with our employees and staff members that the way things were done five or ten years ago is very different from how they are done today, or will be done in five or ten years from now. Employees’ responsibilities, job assignments, and work processes change, and we make the implementation as smooth as possible. This change is continuous, and we have made it part of every employee’s job description.

 

Competitive Challenges: Developing Human Capital

AFAF through experience has come to the conclusion that we are in an industry that not only thrives through experience, change, and technology, but also on our ability to manage human capital. Human capital is very important in our organization and we regard it as the most important resource we have available. Not only cause it is limited in quantity, or that “good help is hard to find,” but the reason is that we believe in an end product not of good quality but rather a work of art to be appreciated.

Human capital is a term that gives value of our knowledge, skills, experience, and capabilities that do not show up on our balance sheet, but do have a tremendous impact on our performance. Our human capital is a resource that cannot be managed as a product or technology because it is very fluid.

AFAF has developed a strategy to ensure superior knowledge, skills, and experience within our workforce. Our staffing program focuses on identifying, recruiting, and hiring the best brightest talent available. We also believe that every employee should be given the chance to develop his or her skills before judgment is passed.

We at AFAF have created a program for our employees where we provide developmental assignments and make certain that job duties and requirements are flexible enough to allow for growth and learning.

 

Competitive Challenges: Market Responsiveness

Meeting our clients’ expectations is essential for us such as their requirements of quality, innovation, variety, and responsiveness. We have been able to maintain a certain standard through our employees.

Some of our clients viewed our field of work as doors, windows, and glass. But through our highly trained employees we have managed to offer our clients not only a mere product but rather an experience. Responding to the market’s needs is a skill we have perfected through an excellent management of human resources.

 

Competitive Challenges: Containing Cost

Although there is increasing pressure from clients and the market to lower costs, we still insist on improving productivity to maximize our efficiency. Labor costs are one of the largest expenditures in our organization since we are in an industry where not only do we offer a product but a service by being knowledge-intensive.

Since we do not believe that the minimum law requirement for our human resource is sufficient, we always make sure that at AFAF we are also providing an ethical and moral requirement to our labors that is far above the set regulations.

Also it is part of our policy to not downsize but rather to right-size. Instead of growing to fast to keep up with demand and the requiring to downsize, a large part of our contract assignments are outsourced to specialized companies to avoid any lay-offs.


Extracurricular Activities:

It is part of AFAF’s policy to encourage employees to use their creativity. One of these events is the highly publicized 1st Red Bull Flugtag, which was held at the Dubai Creek Park on the 25th of November 2005. Through creative design and proper implementation during the manufacturing process by Al Fayha Aluminium Factory, the “Dragofly team” led by Michel Nader was able to receive 2nd place by flying unpropelled 18 meters. For more information log onto www.redbullflugtag.ae.


Method Statement:

 

Pricing:

Beginning from the Tender stage, our estimation engineers carefully review the drawings and specifications of a project to ensure the proper estimation of all aspects of the aluminum and glazing offer. They carefully liaise with the customer on any potential discrepancies or non-clarities to ensure an accurate estimate is given, and eliminate the potential of future conflict during the execution, which is an advantage to both parties.

 

Planning/Program:

Programs for elements of the order are prepared based on the approval construction program supplied by the Main Contractor. The Production Manager in consultation with fabrication staff plans procurement, production and finishing.

Programs of work are prepared using MS Project software, and the Production Manager reviews all the programs prior to submission. Co-ordination of the various phases of work is carried out with the Main Contractor as necessary to achieve the project objectives.

Programs will include the procurement, fabrication, assembly, delivery and erection phases as necessary. Company staff are always available to coordinate with clients concerning the progress of work at site and manufacturing plant.

Material and Accessories:

Once a project is awarded, the project coordinator meets with the customer to ensure that all his demands and requirements are met. Only high quality samples and accessories meeting the international standards are submitted for approval, along with the required supplier technical data. AFAF always thrives to ensure that the customer is totally satisfied with the range or products available, and goes the extra step to provide additional samples from new suppliers should the customer wish to do so.

 

Design and Drawing Preparation:

Our Chief Engineer carefully coordinates with the customer to ensure that all their design and architectural concepts are met and implemented into the aluminum design. The customer can choose from a wide selection of products available with Al-Fayha, and in certain cases is able to custom make their own designs to promote his personal touch in the project. As necessary, calculations are also incorporated into the drawings to confirm the structural integrity of aluminum connections to withstand the imposed forces and moments, air and water tightness, and building movements.

During the aluminum shop drawing preparations, any discrepancies or problems in the architectural drawings is highlighted to the customer to avoid future conflicts during execution. Furthermore, any potential infeasible design requirement by the customer is also highlighted, and alternatives are proposed that are feasible yet do not sacrifice the quality or design envisioned by the customer.

Preparation and submission of drawings are done in sequence with times that are compatible with the approved programs of work. All shop drawings are thoroughly checked and reviewed by the designated Engineer for the project prior to submittal for approval. Only approved drawings are distributed and used for fabrication and erection at site. Qualified and well-experienced draughts men using the latest CAD drafting software prepare all shop drawings. Our Structural Engineers also rely on STAAD and other supplier software for their structural analysis. If required by the contract, on the completion of aluminium work erection as-built drawings are submitted to the Consultant/Clients.

 

Procurement:

Following the approval of samples and review of the conditions of contract, work orders are prepared by the estimator and approved by the Production Manager. Work orders will be copied to the Production Manager and Sales Engineer. Relevantly technical information will be attached to the orders to correctly describe the specific requirements and approvals given. Furthermore, the program of works is always considered when placing orders to ensure the timely manner of material receipt, in order not to jeopardize the project completion time.

 

Material Receipt:

All incoming material is carefully inspected by our Quality Engineer to ensure it is defect free and in compliance with the approved samples. Aluminum are only purchased from companies complying with British Standards for Aluminum Extrusion, to monitor the extrusion, alloys, tolerances, tempering and coatings. Glass is also checked for compliance with BS and ASTM standards for double-glazing, tempering and other heat treatment, lamination, and other aspects. All other accessories are checked using their referenced standards for conformity and approved samples.

The compliant material is carefully labeled and stored to ensure it is used for the correct project. All non-compliant material is returned to the supplier, and Al-Fayha always tries to ensure that alternative sources are available so the project program is not affected, regardless of the item required.

Fabrication:

All fabrication is carefully done to ensure the proper tolerances, finishes, assembly, performance and quality of the finished product are not compromised in any phase of fabrication. The design department carefully prepares the relevant cutting lists and fabrication drawings using CAD and custom made sheets to simplify the production process and ensure it is error-free. Samples are regularly erected at site to ensure their compatibility with site conditions.

From the taping of the material, to the cutting, machining, assembly and packaging, a foreman is always present to ensure the work is done with the required quality. The standards used for this monitoring are a combination of the different supplier recommendations, and those gained through experience from years in the industry.

Several tests are performed on the finished products to ensure their proper performance and quality. This reduces the probability of defective material being installed at site, causing problems during the snagging and handing over phase.

 

Release for Delivery and Shipment to Site:

Once the Quality Engineer approves the finished material, it is carefully stored until it is to be loaded to the site. The loading process is carefully done under the supervision of the Quality Engineer to ensure that it is safely transported to the site without damages occurring during the trip. Furthermore, any damaged materials received by the site stores are returned to the factory to ensure that they are not installed at site leading to the dissatisfaction of the customer.

The delivery date of the material is coordinated with the site condition, based on the input from the site engineer and the Main Contractor input. If required by the contract, the Consultant/Client is to be notified about the delivery so he may inspect the incoming material and confirm that it is to his compliance.

 

Site Storage:

AFAF coordinates with the Main Contractor to always ensure adequate storage space is provided at site for the proper storage of incoming material. This is vital to avoid damages to stored material and the sacrificing of quality. Different material is stored in different methods, based on its geometry and type. Glass panels are stored in customized A-Frames to ensure that they are stacked stress free, aluminum frames are stacked in a way to prevent inadvertent scratching of the coated surface, gaskets and silicones are stored in a clean environment to avoid contamination, and so on.

The storage is prepared to ensure access is only for AFAF personnel, so we may assume complete responsibility for the quality of the material. A storage foreman is assigned to ensure the compliance of all incoming material, and the proper distribution of material in the site so the erection is smooth and delay-free.

 

Erection:

Depending on the size of the project, a team consisting of project engineers and foremen is assigned to ensure the proper execution of the works to the satisfaction of the customer. The project engineer carefully studies the project and prepares the necessary resources to complete the job within the timeline of the project program.

The Project Engineer is introduced to the Main Contractor and customer and commences the necessary coordination works. Items of importance are erection sequences of different subcontractors, setting out, agreed tolerances, grid references and levels, and other aspects of erection. All the approved drawings are given to the project engineer with clear markings for the installation locations in terms of the plan, grids and benchmarks. Any potential problems in the sequence of works are highlighted to the Main Contractor at an early stage to avoid future clashes and time loss.

The erection process is done in accordance with the accepted industry standards. These are a combination of the various supplier recommendations, experience, and technical know-how. The suppliers are often called to the site to inspect and confirm the fixing is done as per their requirements. This is especially true to anchoring systems, such as bolts, chemical anchors, cast-in channels, and other systems. Furthermore, silicone and gasket suppliers are also called to ensure the proper application of their products, as to avoid any faults due to fabrication.

A team of experienced foremen is in charge of the monitoring of the quality and progress of works. They will highlight any problems to the project engineer who will take all necessary action to ensure that the progress is not jeopardized. The Main Contractor is always kept informed of developments and problems at site.

Weekly progress updates are prepared by the project engineer to monitor the speed of work, and ensure that it is in line with the project program. Any adjustment in terms of manpower or equipment is made to ensure the end date is met. Furthermore, correspondence is maintained with the Main Contractor to highlight problems in access, site clearances and others.

Finally, the project engineer will routinely offer various areas for the inspection of the Consultant, as per the project requirement, to ensure that work is being done in a satisfactory manner, and that no rejections will be made later on that may delay the project. All the snags and comments are rectified to ensure the handing over process is smooth and satisfactory to all parties concerned.