Floor Type Boring & Milling Machine (BF-I)

Major Outcomes of Replacement

Year of Manufacturing 1970
➢ Impact On Production
Operation Health & Reliability = 20% (KRL -TAR)
• Increase in Production Capacity up to 30 %
• Decrease in Production cost 30-40 %
Current Product / Business Area
• Components of Industrial Boilers & Pressure Vessels
• Thermal Power Plants, Hydal Power Plants ➢ Impact On Business Portfolio
• Sugar, Cement and Defense sector.
• Components of Special/Strategic Machine Tools
Required Replacement • Heavy Parts of Thermal, Hydel & NPPs.
2

CNC Floor Type Boring & Milling Machine (5 Axis)

➢ Quality Improvements

Estimated Cost of Replacement = 3.245M (US$) • Improved Product Accuracy & Precision
532.91M (PKR) • Reduction in Rework & Rejection
 Floor Type Boring & Milling Machine (BF-II)
Major Outcomes of Replacement
Year of Manufacturing 1970
➢ Impact On Production
Operation Health & Reliability = 20% (KRL -TAR)
• Increase in Production Capacity up to 30 %
• Decrease in Production cost 30-40 %
Current Product / Business Area
• Components of Industrial Boilers & Pressure Vessels
• Thermal Power Plants, Hydal Power Plants ➢ Impact On Business Portfolio
• Sugar, Cement and Defense sector.
• Components of Special/Strategic Machine Tools
Required Replacement • Heavy Parts of Thermal, Hydel & NPPs.
Floor Type Boring & Milling Machine
➢ Quality Improvements

Estimated Cost of Replacement = 0.6M (US$) • Improved Product Accuracy & Precision
98.51M (PKR) • Reduction in Rework & Rejection
 Radial Drilling Machine (DR-I)
Major Outcomes of Replacement
Year of Manufacturing 1969
➢ Impact On Production
Operation Health & Reliability = 40% (KRL -TAR)
• Increase in Production Capacity up to 40 %
• Decrease in Production cost 40-50 %
Current Product / Business Area
• Components of Industrial Boilers & Pressure Vessels
• Thermal Power Plants, Hydal Power Plants ➢ Impact On Business Portfolio
• Defense sector and Petro Chemical Industry.
• Components of Special/Strategic Machine Tools
Required Replacement • Heavy Parts of Thermal, Hydel and Structures.
Radial Drilling Machine (Max Dia 125 mm)
➢ Quality Improvements

Estimated Cost of Replacement = 0.15M (US$) • Improved Product Accuracy & Precision
24.672M (PKR) • Reduction in Rework & Rejection
 Radial Drilling Machine (DR-II)
Major Outcomes of Replacement
Year of Manufacturing 1968
➢ Impact On Production
Operation Health & Reliability = 20% (KRL -TAR)
• Increase in Production Capacity up to 40 %
• Decrease in Production cost 40-50 %
Current Product / Business Area
• Components of Industrial Boilers & Pressure Vessels
• Thermal Power Plants, Hydal Power Plants ➢ Impact On Business Portfolio
• Defense sector and Petro Chemical Industry.
• Components of Special/Strategic Machine Tools
Required Replacement • Heavy Parts of Thermal, Hydel and Structures.
Radial Drilling Machine (Max Dia 125 mm)
➢ Quality Improvements

Estimated Cost of Replacement = 0.15M (US$) • Improved Product Accuracy & Precision
24.672M (PKR) • Reduction in Rework & Rejection
 Heavy Duty Lathe Machine (HL-I)
Year of Manufacturing 1968
Operation Health & Reliability = 39% (KRL -TAR)
Current Product / Business Area
• Components of Industrial Boilers.
• Hydal Power Plants and Steam Turbines.
• Defense sector and Sugar Industry.
Required Replacement
CNC Heavy Duty Lathe (Max Length 8000 mm)
Estimated Cost of Replacement = 0.8M (US$)
131.58M (PKR)
Major Outcomes of Replacement
➢ Impact On Production
• Increase in Production Capacity up to 30 %
• Decrease in Production cost 30-40 %
➢ Impact On Business Portfolio
• Components of Special/Strategic Machine Tools
• Heavy Parts of Steam Turbine, Hydel and Sugar
Sector.
➢ Quality Improvements
• Improved Product Accuracy & Precision.
• Enhancement in Product Surface Finish.
• Reduction in Rework & Rejection.
 Heavy Duty Lathe Machine (HL-6)
Year of Manufacturing 1968
Operation Health & Reliability = 39 % (KRL -TAR)
Current Product / Business Area
• Components of Industrial Boilers.
• Hydal Power Plants and Cement Sector.
• Defense sector and Sugar Industry.
Required Replacement
CNC Lathe Machine (Max Length 3000 mm)
Estimated Cost of Replacement = 0.3M (US$)
49.25M (PKR)
Major Outcomes of Replacement
➢ Impact On Production
• Increase in Production Capacity up to 40 %
• Decrease in Production cost 30-40 %
➢ Impact On Business Portfolio
• Components of Special/Strategic Machine Tools
• Heavy Parts of Steam Turbine, Hydel and Sugar
Sector.
➢ Quality Improvements
• Improved Product Accuracy & Precision.
• Enhancement in Product Surface Finish.
• Reduction in Rework & Rejection.
 Heavy Duty Lathe Machine (HL-9)
Year of Manufacturing 1968
Operation Health & Reliability = 20% (KRL -TAR)
Current Product / Business Area
• Components of Industrial Boilers.
• Hydal Power Plants and Steam Turbines.
• Defense sector and Sugar Industry.
Required Replacement
CNC Heavy Duty Lathe (Max Length 8000 mm)
Estimated Cost of Replacement = 0.30M (US$)
49.25M (PKR)
Major Outcomes of Replacement
➢ Impact On Production
• Increase in Production Capacity up to 30 %
• Decrease in Production cost 30-40 %
➢ Impact On Business Portfolio
• Components of Special/Strategic Machine Tools
• Heavy Parts of Steam Turbine, Hydel and Sugar
Sector.
➢ Quality Improvements
• Improved Product Accuracy & Precision.
• Enhancement in Product Surface Finish.
• Reduction in Rework & Rejection.
 Vertical Turning & Boring Machine (BVT-II)
Major Outcomes of Replacement
Year of Manufacturing 1969
➢ Impact On Production
Operation Health & Reliability = 20% (KRL -TAR)
• Increase in Production Capacity up to 40 %
• Decrease in Production cost 40-50 %
Current Product / Business Area
• Components of Petrochemical Industry.
• Hydal Power Plants. ➢ Impact On Business Portfolio
• Defense sector and Sugar Industry.
• Components of Special/Strategic Machine Tools
Required Replacement • Heavy Parts of Chemical Industry, Hydel and Sugar
Sector.
CNC Vertical Turning and Boring (Max Dia 6000 mm)
➢ Quality Improvements
Estimated Cost of Replacement = 1.3M (US$)
213.82M (PKR) • Improved Product Accuracy & Precision.
• Reduction in Rework & Rejection.
 Plano Milling Machine (MLP-I)
Major Outcomes of Replacement
Year of Manufacturing 1969
➢ Impact On Production
Operation Health & Reliability = 20% (KRL -TAR)
• Increase in Production Capacity up to 40 %
• Decrease in Production cost 20-30 %
Current Product / Business Area
• Components of Heat Exchangers.
• Hydal Power Plants and Process Boilers. ➢ Impact On Business Portfolio
• Defense sector and Sugar Industry
• Cement Industry. • Components of Special/Strategic Machine Tools
• Heavy Parts of Chemical Industry, Hydel and Sugar
Sector.
Required Replacement
CNC Plano Milling Machine (1500 x 6000 mm) ➢ Quality Improvements

Estimated Cost of Replacement = 0.49M (US$) • Improved Product Accuracy & Precision.
80.594M (PKR) • Improved Surface Finish.
• Reduction in Rework & Rejection.
 Cylindrical Grinder (CG-I)
Major Outcomes of Replacement
Year of Manufacturing 1968
➢ Impact On Production
Operation Health & Reliability = 20% (KRL -TAR)
• Increase in Production Capacity up to 40 %
• Decrease in Production cost 20-30 %
Current Product / Business Area
• Components of Strategic Machine Tools.
• Hydal Power Plants. ➢ Impact On Business Portfolio
• Boiler and Oil Gas Industry.
• Cement Industry. • Components of Special/Strategic Machine Tools
• Parts of Heavy Defense automobiles.
• Enchantment in Commercial Production Sector.
Required Replacement
CNC Plano Milling Machine (1500 x 6000 mm) ➢ Quality Improvements

Estimated Cost of Replacement = 0.20M (US$) • Improved Product Accuracy & Precision.
32.83M (PKR) • Improved Surface Finish.
• Reduction in Rework & Rejection.
 Vertical Turning & Boring Machine (BVT-3)
(Refurbishment Required)
Year of Manufacturing 1968
Operation Health & Reliability = 39% (KRL -TAR)
Current Product / Business Area
• Components of Industrial Boilers.
• Hydal Power Plants and PK-Series.
• Defense sector and Petrochemical Industry.
Maintenance Summary
➢ Mechanical
• Hydraulic Shifting Issues
• Vertical Head Feed and Rapid Fault
• Taper in slides of Vertical Head
• Main Gear Box Oil leakage problem
• Cross rail locking problem
➢ Electrical

Specifications • Electromagnetic Clutch Fault.

Dia of Table = 2250 mm • Feed Fault.
Max Turning Dia = 2500 mm
 Horizontal Lathe Machine (HL-13)
(Refurbishment Required)
Maintenance Summary
Year of Manufacturing 1970
➢ Mechanical
Operation Health & Reliability = 39% (KRL -TAR)
• Bridge Locks and oil pump fault.
• Table Bed way is pitted with abnormal sounds
Current Product / Business Area vertical head gears.
• Commercial. • Oil pressure to table lift locking mechanism is
• Defense. faulty.
• Process and Industrial Boilers. • Vertical right head stock gears are not matched.
• Oil leakages & Hydraulic pump coupling worn out.
Specifications
Swing over Bed = 630 mm ➢ Electrical
Distance b/w Centers = 1400 mm
• Electromagnetic Clutch Fault.
• Feed Fault.