hmc
TRANSCRIPT
This report includes my observations along with some gathered facts and figures about Heavy Mechanical Complex, situated at Taxila. The report is submitted as per the authorities instructions in regard of SMME’s 2nd semester students’ visit to HMC dated 3 / 5 / 2011. The report covers the following major aspects about the industry.IntroductionLevel of TechnologyHuman ResourceQuality ControlResearchConclusions
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Dedicated to my Parents who have never failed to give me financial and moral support, for giving all my needs during the time. Who made me believe that even the largest task can be accomplished if it is done one step at a time.
Table of Contents
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1. Introduction to Heavy Mechanical Complex (HMC), Taxila.a) Location and Areab) Basic Layout
2. Level of Technology. a) State of Technical Developmentb) Major Machineriesc) Processing Facilities
3. Human Resource Department (HR). a) Classification of Manpowerb) Welfare of Employees
4. Quality Control. a) Standards Followedb) Testing Facilities
5. Waste Management. 6. Inventory Management. 7. Production Planning.
a) Productsb) Production Plan
8. Research Initiatives.
9. Industrial Safety. a) Significance of industrial Safetyb) Safety measures at HMC
10. Suggestions.
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Special thanks to:
Engr. Rehan Zahid for briefing us about the machinery and phenomenon during our visit to Heavy Mechanical Complex, Taxila.
Engr. Waseem Waheed for his guidance and support during the compilation of this report.
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Introduction to HMC
Heavy Mechanical Complex (Private) Limited is a leading engineering goods manufacturing enterprise in Pakistan located at Taxila about 35 Kilometers north of capital Islamabad. It was established in 1970 under the ministry of production. Mechanical works started commercial production in 1971 and Foundry and Forge works started commercial production in 1977. It is a professionally managed progressive organization with over 160,000 sq. meters covered facilities and 1,100 employees.
HMC have the resources to handle large projects with demanding delivery schedules. The status of HMC today is that no industry is facilitated with no government funding, it earn its living on his own. Being the largest and most extensive fabrication and machining facility equipped with state of the art
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technology. HMC provide manufacturing services both on our own or customers design.
HMC is the mother industry of Pakistan. It has gained rich experience in designing and manufacturing of large projects through collaboration with internationally reputed engineering organizations. All its processing facilities are in-house including Designing, Fabrication, Machining, Iron and Steel Castings, Forgings, Heat Treatment, Assembly, Sand Blasting, Painting and Galvanizing etc.
Managing director is the head of the organization who is appointed by the board of governors. MD is assisted by the managers of different departments’ e-g finance, marketing and works. Then there are shop and floor managers who supervised their workers.
The factory includes following shops:
1. FABRICATION SHOP2. MACHINE SHOP3. FORGE SHOP4. FOUNDRY
Level of TechnologyAs mentioned earlier Heavy Mechanical Complex was established in 70’s so most of the machinery is outdated and have fulfilled to its job. However the engineers and technicians running the association are qualified and are familiar to modern techniques of designing and manufacturing.
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Most of the machinery is imported from china and it is very disgusting to see that although we are now capable of manufacturing such machines but we still don’t bother. This aspect of our laziness directly affects the economy of our country.
Modern manufacturing processes are applied for rapid and large scale production.
Some of the machines used in various shops at HMC are enlisted below:
Gas Cutter CNC Flame Cutter Lathe Machine Gear Hobing Machine Planner and Milling Machine Slotting Machine Drill Machine Gas Welding Machine Hydraulic Press Boring Machine Power Machine Blast Furnance
HMC have gained rich experience in designing and manufacturing of large projects through collaboration with internationally reputed engineering organizations. All its processing facilities are in-house including
Designing Fabrication
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Iron and Steel Castings Machining Forging Heat Treatment Sand Blasting Painting Assembly Galvanizing etc.
Human Resource Department(HR) Human resource refers to the man power of any type of organization or group. However, considering the modern manufacturing industries it directly means the technical/trained staff available to that industry. The term human resource does not only mean the availability of man power but also counts for the appropriate use of man power.
The human resource department at HMC can be classified into five majors as below:-
Engineers
This category includes highly qualified professionals who have done bachelors, master or PhD from recognized universities worldwide. These are further divided into three categories
Production Engineers
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Tool and Design Engineers
Quality Control Engineers
Mechanics/Technicians
This category includes diploma holders in various engineering technologies mainly mechanical, chemical, and metallurgical etc. They are the operators of machines who control and handle all the machinery. These technicians manufacture and assemble the parts according to the drawing given by the floor engineer. They are qualified from various technical training institutes nationwide such as Polytechnic, TEVTA, Swedish, etc. Then, sent to the floor for apprenticeship for 2 years.
Management
This category includes those peoples who run the organization. The management compromises of directors, managers, shops incharge, supervisors, etc. These peoples are responsible for the stability of the association and its growth. They make policies and define the behavior of the company towards others. In HMC highly experienced, qualified, and keen peoples are a part of management. The high officials aim to the growth and overall success of the HMC in the field of competition.
Marketing
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This category includes qualified marketing personals who act as a junction between the customer and the industry. These people are responsible for communicating with the outer world, and to collect orders from different companies nationwide.
In the near future, as said by the guide, HMC is planning to take orders from worldwide construction companies and import its product. All the credit of this achievement goes to the marketing department.
Labor/Staff
The category includes non-technical staff such as labors, drivers, clerks, storekeepers, guards, cooks, sweepers, peons, etc.
Observations
HMC takes good care of its employees as they are very handsomely paid and are given special privileges. Not only to the management or engineers but other staff is given such benefits as well. Some of these benefits include free medical, free housing, education for children, pick and drop services, etc. Further, in case of unfortunate accidental death the families of officers are awarded 10 lacks rupees for their consolation and the families of workers are given 2 lack.
Quality ControlHMC is ISO 9001 certified and is authorized to use 4 ASME stamps U, U2, S & PP for equipment manufactured
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according to ASME code. The manufacturing is backed by excellent quality control and testing facilities to meet the product and customer quality requirements. 3rd party inspection facilities are also available, where required.
Inspection and testing is carried out as per the procedures established for ISO 9001 QA System and ASME Code procedures. The inspection & testing activities are well backed up with the following facilities:
Material Testing Lab The laboratory has the facility for checking chemical analysis of iron and steels, non ferrous metals by spectrographic and wet chemical methods. Metallographic Examination, Mechanical testing.
Non Destructive Examination
The facility consists of VT, UT, MT, PT, RT (Max 80mm thickness).
Instrument Calibration Laboratory
This laboratory has facilities for calibration of measuring and testing devices such as pressure testing gauges, thermocouple, temperature recorders, measuring devices
Waste ManagementOne of the biggest task faced by the industries in the waste treatment. Industrial waste includes gases, slag, solid waste, etc.
The exhaust system of forge and foundry shop sends obnoxious gasses right out of the shops into the environment. This successfully creates no gas zone inside the shops and the health
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of workers is secured but the overall environment and nearby residencies, including HMC Colony, is seriously threatened in the long run.
There is no special treatment plant for the waste gasses. So it should be taken seriously and waste gases treatment plant must be made.
The other issue is solid waste. As HMC is all about working with metal a lot of metal is disposed off. This waste metal is recycled and being sold to the local industries.
The slag which results from the casting process is buried at the back of the factory in unpopulated area. However, as there are chances of radiation exposure from slag, it also requires proper treatment.
Inventory ManagementThe inventory management at HMC Taxila is quite satisfactory. Whenever a new order is placed, more metal is required and hence brought to the factory. This metal and other raw materials are handled with good care and it is made sure that nothing should be wasted. Also the machinery, as mentioned earlier, is very old and outdated but kept is good condition. This is due to the fact that management services do their jobs on regular basis. Whenever any machine encounters a problem, it is quickly sent to get fixed. The entire inventory is managed using both digital and traditional database techniques. Floor engineer keeps
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comprehensive record of all the movement of material, machinery, and employees.
Production Planning As already mentioned, HMC is the leading manufacturing industry of the country, so it manufactures and sells a large variety of products. The productivity of any industry directly depends upon the availability and fulfillment of the orders and their time to time delivery. All this is not possible until a sound and secure production planning.
At present the output of HMC is mostly heaviest machinery around the country and the organization is fulfilling the needs of most of the renowned national and multi-national companies including Heavy Industries Taxila (HIT).
The company is manufacturing:
Cement Plants Sugar plants Chemical/petro chemical plants Oil & gas processing plants Industrial steam boilers Thermal and Hydel power plants Railway equipment Road construction machinery Overhead travelling cranes Chassis for Trucks and busses
This reflects the master production management and planning sample of HMC.
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The currents production plan of HMC is as follows:-
The production is compiled in three steps
First of all orders are collected and their cost analysis is done. After cost analysis the efficiency of the product is calculated.
After this, if the product is feasible, the next step is designing and modeling. This is done via Computer Aided Designing and manual drafting. Engineers from different disciplines put together their minds for compilation of the design.
Then comes the real work of scratching a gold piece from stone. The job is manufactured from the scrap in different shops. Different parts of job are prepared in various shops and then assembled together in the machine and auxiliary shop.
Research Initiatives This is the biggest flaw of the heavy mechanical complex that no research is being carried out at all. Also the staff workers are trained on traditional methods and are hence hesitant to adopt new technologies and techniques.
During our visit, we come across some foreign engineers who are hired for some complex jobs and the painful fact here is that HMC is not arranging modern training programs for its own workers.
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The biggest barrier in the way of modernization and research is the financial crisis as government has stopped funding HMC. Research initiatives require a lot of budget which is the right of such a unit, but our government is ignoring the fact. But despite of all these hurdles HMC is competing among the all nationwide running companies.
Industrial Safety Industrial safety is the key to success for any industry. The importance of manpower and resources for an industry can never be over emphasized. So, to make sure that the company must not face any accident industrial safety precautions weighs almost 80%, the rest 20% accidents are due to third class machineries. Such accidents cause loss to both manpower and the resources.
Heavy Mechanical Complex has defined a comprehensive set of precautions and the beauty of the fact is that strict measures are taken to enforce these safety rules.
Some of the safety measurements taken at HMC are mentioned in the paragraph below:
A clearly marked path is reserved for passing by through the machines in all shops especially in fabrication and machine shop. Where innumerable labors and staff personals have to pass by. If these passages were not reserved, then these non-technical workers would cast a lot of disturbance for the technicians and could also be the reason for accidents. The workers and provided with special overall suites called DANGARIES for
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their safety. Where there is needed, gloves and cover shoes are also provided by the authorities.
One thing that actually makes the place unsecure is the absence of a proper fire brigade system. In any case, the fire vehicles will take minimum of 30 minutes to approach HMC from Wah Cantt.
Suggestions No doubt that HMC is manufacturing products at a very fast rate but the fact remains the same that the machinery is mostly outdated. Most of the machines need replacement or up gradation. The old machinery is hazardous to health also as incidents of breakage have been reported by the guide.
As far as the replacement of machinery is related, we must manufacture new machinery our self. HMC is capable of fulfilling this job.
Latest manufacturing techniques must be introduced for more rapid and efficient production. Special training courses should be arranged for the worker so that they can easily digest the upcoming revolutionary technologies.
It is a fact that the employees are paid gently but due the inflation and lack of capital they are facing many problems. Officers were given pay raise and extra bonus along with luxurious facilities but the workers were deprived of such privileges. The shops are working 24/7 so the work load on employees is too much and they should be given more time breaks for their better health.
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It is a said that
“Cost of quality does not emerge from practicing quality rather it emerges from when you don’t practice quality”
Lt Col (R) Naweed HassanSMME
When fake or low class products are rejected in the market than such rejections cast a lot of loss to the industry. So Quality Control must be improved and upgraded to the latest systems used and trusted worldwide. Qualified professionals must be hired for checking the quality of the products.
A proper waste treatment plant must be installed at once for secure treatment of waste gases and slag.
Federal Government should pass a parliamentary bill through which a reasonable fund must be allocated to HMC on annual basis. Government must also help the industry to establish its own fire brigade system, as the safety of the citizens is the basic responsibility of the government.
ConclusionsConsidering all the facts above, one can easily conclude that how significant Heavy Mechanical Complex (HMC) is for Pakistan. The industry manufactures a lot of products and does his part by fulfilling the needs of nation.
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Nowadays PAKISTAN is suffering from shortage of sugar. To fulfill the present need of sugar, new plants have to be set up. HMC is manufacturing such plants on a large scale.
HMC has a lot of importance for the country, as importing such machinery is very expensive and can further harm the downsized economical conditions of Pakistan. HMC has been much neglected by the government in spite of the fact it has potential to grow explosively.
Gradually, due to the sincere efforts of the management, now HMC is rising on its feet again and is growing day by day. But it has to cover a long way before it can compete in the international market.
By taking a sight on the history of industrial development of PAKISTAN, and comparing it with HMC, it becomes admirable that every goal can be achieved by strong determination and hard work.
I salute to all those great people who work day and
night and sacrifices for the prosperity of their nation
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and country. We are just because of such brave souls.
BIBLIOGRAPHY
Work Cited
Heavy Mechanical Complex Web Site. Home Page. http://www.hmc.com.pk/
Handouts distributed among students by HMC staff
Lecture by Lt Col (R) Naweed Hassan, DD MRC & CAC Coordinator, School of Mechanical and Manufacturing Engineering, NUST. [email protected]
Image from Google Earth Software (Download link:
http://www.google.com/earth/download/ge/agree.html)