Machine and Fitting Shop Newsletter 2014

 

2014 has been a tedious year. But

in the middle of the entire plant

hustle Machine and fitting shop

team has surpassed expectations.

With improvements ranging from

Machines Shop CM o LFC target

achievement & enhancing JQP

quality of Shop Machinists, team

has done it. All this yet safe & injury

free. With such high performance

bar is set even higher in 2015, so

team stay motivated, stay energetic

& Wish Us Best of Luck for 2015! 

ttaullah Shah Bokhari

htsham hmad 

People Development & Training

Machine Shop Achievements

Machine shop has been the most loaded area of shop this

year with jobs lined up one after the other. Following are

some of the major functional achievements this year,

Shop Machinist JQPs  re-appraised and questions were

increased by 100%

AMM-II Syn. Compressor  parts accurate Machining

TP-1403 GB –  being the biggest site GB was refurbished

1st 

 time

NGBC  - Pneumatic pump off-eccentric casing machining

and accurate drilling

PHT-2503 Train shaft and all other parts refurbishment 

& machining in the crunch time of Plant-I

10 ea. Offsite Deep Well Turbines  Extensive machining

and reclamation

Measuring Tools cannibalization and reclamation  

observed the saving of 1.1 Million

EPQL Cooling Tower GB machining for casing alignment

with gears and cover

Zero injury

TRIR is 0.00

D-Level committee # 25 shown

continuous improvement

Measuring Tools Cannibalization

A pure process improvement project

aimed at streamlining Tools

Cannibalization and reclamation. As a

result of the activity over 72% of the

damaged measuring tools were

recovered having a realized fixed cost

saving of 1.1 M.

6 sigma

Universal Balancing connectorsA pure process improvement project

aimed at saving 700 Man-hrs. Per year.

Universal Type Mandrels and Couplers

were designed and in-house

fabricated. As a result of the activity

over 700 Man-hrs/year material

saving is expected  in future along with

huge machining Man-hrs. Saving.

Year Round Appreciations

MACHINE SHOP TASK TEAMEnsured 100% closure of 2014 recommendations

1. Machines Taper was removed from 02 machines 1st 

 time 

2. Short term CM Plan execution for Machine shop Machines 

3. 50% of Machines Civil related problem were addressed  

4. Machining time was reduced by introducing some new

bars

Fabrication Shop

In-house LFC PO Closure

This year, machine and fitting shop has brought up

about a saving of Rs. 21.2 M  through in-house

replenishment and refurbishment orders for LFC.  

100% increase in replenishment orders from

Machine Sho

Highlights 2014

Shop Machinists was trained to operate Boring Mill

Shop Machinist JQPs Quality Enhancement

Training of Personnel on SAP  

Offsite Pumps Overhauling 

Through Technical Talk Program

HSE

SPOT AWARDS Level 2 – Governor Calibration Bench

Level 2 – PSVs calibration Record per day

While TEAM received appreciation at

TP-1403 GB Refurbishment

CPI Exercise of Plant-II PSV spares

P-2503 Shafts and other Parts before time

Machining

NGBC Pneumatic Pump Machining

Syn. Compressor machining

Measuring Tools reclamation

Offsite pumps Refurbishment

The  TEAM 

Governor Calibration Bench

Universal Balancin Connectors

Excellent Su ort in Both Plant outa es

TP-1403 GB Refurbishment

Short Term Machine CM Plan Execution

LFC In-house PO closure increase d b 100%

 

Saving of 16M through Replenishment

CPI Exercise of Plant-II PSV S ares

Measuring Tools Cannibalization

Syn. Compressor, NGBC & P-2503 Machining

33 PSVs calibration per day Record. In 2014.More than 500 PSV’s were calibrated 

OUR GREATEST PLEASEURE IS DOING WHAT OTHERS CAN’T  

TEAM discovered and executed an 

idea of in-house PGPL Governor 

Calibration. This facility will be

commissioned in 2015 and will eventually

result in saving of Man-hrs. for sending

PGPL Governor to OEM shop as well as cost.