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!

Highlights 2014

The

TEAM

Governor Calibration Bench

Universal Balancing Connectors
Excellent Support in Both Plant outages
TP-1403 GB Refurbishment

Attaullah Shah Bokhari

Ahtsham Ahmad

HSE

Short Term Machine CM Plan Execution

LFC In-house PO closure increase d by 100%

Syn. Compressor, NGBC & P-2503 Machining

CPI Exercise of Plant-II PSV Spares

Saving of 16M through

ReplenishmentShop
Fabrication
Orders
33 PSVs calibration per day Record. In 2014. More than 500 PSVs were calibrated

Measuring Tools Cannibalization

Machine and Fitting Shop Newsletter

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

2014

MACHINE SHOP TASK TEAM

Ensured 100% closure of 2014 recommendations
1.
2.
3.
4.

Machines Taper was removed from 02 machines 1st time

Short term CM Plan execution for Machine shop Machines
50% of Machines Civil related problem were addressed
Machining time was reduced by introducing some new
bars

In-house LFC PO Closure

Zero injury
TRIR is 0.00
D-Level committee # 25 shown
continuous improvement

6 sigma
Universal Balancing connectors
A 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.

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.

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 Shop

People Development & Training

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
OUR GREATEST PLEASEURE IS DOING WHAT OTHERS CANT
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.

Year Round Appreciations

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