Electrical Department

MTO Report

Name: Muhammad Khubaib Rauf

Degree: B.Sc Electrical Engineering
University: NFC IEFR Faisalabad (UET Lahore)
Designation: Management Trainee Officer
Department: Electrical
HOD: M. Rizwan Munir
Reporting Manager: M. Shahzad
Joining Date: 07-09-2023

Kay & Emms (Pvt) Ltd.

• Introduction:

Company’s Vision:

To be the best of the knits through culture of excellence and be a meaningful contributor to the
society.

Company’s Mission:

Kay & Emms is a multi-cultural global corporation with commitment to social and environment
responsibilities. The focus is to be the preferred vendor for knit wear products with highest
emphasis on customer service, innovation, quality, and creative design thus providing a complete
package of client satisfaction.

Company’s Values:

➢ Innovation
➢ Sustainability
➢ Diversity
➢ Quality
➢ Integrity

• Objectives:
The primary objective of my tenure as a Management Trainee Officer (MTO) specializing in the
Electrical Department is to acquire comprehensive hands-on experience and knowledge in
electrical systems, maintenance, and operations within the garment firm. This includes developing
a deep understanding of the intricacies of electrical infrastructure, equipment, and technology
specific to the garment manufacturing industry.
Skill Development:

Acquire and enhance technical skills in electrical maintenance, troubleshooting, and system
optimization.

Project Leadership:

Gained practical experience by leading and participating in electrical projects aimed at improving
efficiency, reducing downtime, and ensuring compliance with safety standards.

Team Collaboration:

Collaborate with the Electrical Department team to understand and contribute to collective goals.
Strengthen interpersonal and teamwork skills through active engagement in departmental
initiatives.

Innovation and Sustainability:

Explored opportunities to introduce innovative and sustainable practices within the Electrical
Department, contributing to the firm's commitment to environmental responsibility.

• Scope:
The scope of my role as an MTO Electrical encompasses a wide range of responsibilities and areas
of focus within the Electrical Department. Throughout the 6-month tenure, I am dedicated to
actively contributing to the efficient and reliable functioning of the electrical systems supporting
garment manufacturing processes.

1. Electrical Machines Maintenance:

Engage in routine maintenance activities to ensure the optimal performance of electrical

machines, minimizing downtime and production interruptions.
 2. Troubleshooting and Problem-Solving:

Develop proficiency in identifying and addressing electrical issues promptly, employing

analytical and problem-solving skills to maintain continuous operations.

3. Project Management:

Lead and participate in electrical projects, from conceptualization to execution, focusing

on enhancing efficiency, implementing upgrades, and ensuring the reliability of electrical
infrastructure.

4. Safety Compliance:

Work towards ensuring the Electrical Department's adherence to safety regulations and
standards, prioritizing a secure working environment for all employees.

5. Energy Efficiency:

Explore opportunities to improve energy efficiency by implementing measures such as

energy conservation initiatives and the adoption of sustainable practices.

6. Collaboration with Cross-Functional Teams:

Actively collaborate with members of the Electrical Department as well as other cross-
functional teams to align electrical operations with broader organizational objectives.

• Electrical Department Overview:

The Electrical Department plays a pivotal role in ensuring the seamless functioning of the
manufacturing process by managing, maintaining, and optimizing the electrical infrastructure. This
department is a critical component of the overall operational efficiency and safety standards within
the firm. The key aspects of the Electrical Department include:
1. Infrastructure Management:

• Equipment and Systems: The department oversees a diverse range of electrical

equipment, including but not limited to machinery, control panels, and lighting
systems essential for garment production.

• Power Distribution: Manages the distribution of electrical power throughout the

facility, ensuring a reliable and stable power supply to all areas.

2. Maintenance:

• Preventive Maintenance: Implements proactive measures to prevent equipment

breakdowns and reduce downtime through regular inspections and scheduled
maintenance activities.

• Corrective Maintenance: Utilizes advanced monitoring systems and diagnostic

tools to detect and address electrical faults promptly, minimizing disruptions to
production.

3. Project Implementation:

• Upgrades and Modernization: Undertakes projects aimed at upgrading electrical

systems to incorporate the latest technologies, enhancing efficiency, and improving
overall performance.

• Capacity Enhancement: Plans and executes projects focused on expanding

electrical capacity to accommodate the firm's growth and increased production
demands.

4. Safety and Compliance:

• Regulatory Compliance: Ensures strict adherence to local and international

electrical safety standards, codes, and regulations, promoting a secure and
compliant working environment.
 • Emergency Response: Develops and implements emergency response protocols
to handle electrical emergencies effectively, prioritizing the safety of personnel and
the protection of assets.

5. Energy Management:

• Efficiency Measures: Implements energy-efficient practices and technologies to

reduce overall energy consumption, aligning with the firm's commitment to
sustainability.

• Renewable Energy Integration: Explores opportunities to integrate renewable

energy sources, such as solar power, into the electrical infrastructure to enhance
environmental responsibility.

6. Collaboration with Other Departments:

• Cross-Functional Teams: Works closely with other departments, including

Dyeing, Finishing, and Laundry to ensure the seamless integration of electrical
systems with overall operational objectives.

• Project Coordination: Collaborates on interdisciplinary projects that require

coordination between different departments to achieve collective goals.

The Electrical Department, through its diverse functions, contributes significantly to the firm's
operational excellence, safety, and sustainability initiatives. Its role is integral to maintaining a
technologically advanced, safe, and efficient production environment within the garment
manufacturing facility.
• Job Responsibilities:
1. Troubleshooting of Electrical Faults and Breakdowns:
To ensure continuous and reliable electrical operations by identifying, diagnosing, and
resolving faults and breakdowns. Perform regular inspections to detect potential electrical
issues. Utilization diagnostic tools to troubleshoot and identify the root causes of faults.
Implement effective solutions promptly to minimize downtime. Collaborate with the
maintenance team for complex troubleshooting tasks. Maintain detailed records of
troubleshooting activities for future reference.
2. Energy Costing and Load Analysis:
Optimize energy usage, reduce costs, and ensure that electrical systems support production
demands efficiently. Conduct regular energy audits to assess consumption patterns. Analyze
electrical load and usage trends to identify optimization opportunities. Implement energy-
efficient practices and technologies. Evaluate the cost-effectiveness of energy-saving
measures. Collaborate with relevant departments to align energy usage with production
requirements.
3. Implementation of Electrical Safety Protocols and Compliances:
To create a safe working environment by enforcing and adhering to electrical safety
protocols and regulatory compliances. Develop and implement comprehensive electrical
safety protocols. Conduct regular safety training sessions for departmental staff. Ensure
compliance with local and international electrical safety standards. Conduct safety audits to
identify and rectify potential hazards. Facilitate emergency response drills and ensure the
availability of safety equipment.
4. Inventory Management:
Maintain an organized and efficient inventory of electrical components, tools, and spare
parts. Regularly monitor stock levels of electrical components and equipment. Coordinate
with suppliers for timely procurement of necessary items. Initiate orders based on inventory
levels and project requirements. Keep accurate records of inventory transactions, including
receipts and issues. Conduct periodic audits to reconcile physical inventory with records.
5. Documentation and Reporting:
Maintain accurate records and provide regular reports on the status of electrical systems,
safety compliance, and inventory levels. Document all maintenance activities, equipment
inspections, and troubleshooting processes. Prepare regular reports on the performance of
electrical systems. Include details on energy consumption, safety compliance, and inventory
status in reports. Analyze data to identify trends, areas for improvement, and opportunities
for efficiency enhancement. Communicate findings and recommendations to relevant
stakeholders.
• Projects:
Comprehensive Machine Load Analysis:
The textile industry heavily relies on various machines to carry out essential processes such as
dyeing, finishing and laundry. Understanding the operational efficiency and load characteristics of
these machines is crucial for maintaining productivity and ensuring optimal performance. So, the
comprehensive machine load analysis conducted at Kay & Emms, aimed at determining the rated
and running loads of each machine in each department.

Methodology:
The analysis involved a systematic assessment of each machine's operational parameters, including
power consumption. Data was collected through direct measurements, equipment specifications,
and real-time monitoring during regular production cycles.

Figure 1 : Rated Load from equipment specifications

 Figure 2 : Running Load of Equipment

Machine Wise Report:

The load analysis report is divided into two sections, first is machine wise report which includes
the load of each motor and VFD fitted in the machine. The second is department wise report which
includes the rated and running load of each machine in each department.
 Figure 3 : Machine wise load report

Figure 4 : Department wise load report

Benefits of Load Analysis:
The machine load analysis report serves as a valuable tool for decision-making and strategic
planning. It provides insights into optimizing machine performance, reducing downtime, and
ensuring optimal resource utilization. Integration of these findings into regular maintenance
routines and future expansion plans is recommended.

Load Management:
Current Power Generation Capacity:

Kay &Emms currently possesses a total power generation capacity of 2.6MW. This capacity is
crucial for sustaining operations and meeting production demands. The sources contributing to
our power generation include:
➢ WAPDA Power:
The primary source of power for our operations is the Wapda. We rely on the Wapda for a
significant portion of our energy needs due to its reliability and consistency. We have 3MW
sanctioned load capacity from Wapda.
➢ Solar Power:
In our commitment to sustainability, we have integrated solar power into our energy mix. Solar
panels of 699kW installed on-site contribute to our power generation, reducing our reliance on
traditional energy sources and minimizing our carbon footprint.
➢ Diesel Generators:
To ensure uninterrupted operations, especially during peak demand periods or in case of grid
failures, we have diesel generators as backup power sources. These generators provide a reliable
alternative during emergencies or when additional power is required beyond the capacity of the
grid and solar.
 Existing Generator Capacity
Diesel Engine Load (kW) Load (Amp 70%)
Caterpillar # 1 1020 1285
Caterpillar # 2 648 750
Caterpillar # 3 1020 1285
Total 1882 3320

Machinery Expansion and Load Analysis:

As Kay & Emms planning to expand laundry machines to meet the production demand. So, load
analysis report provided to management for the demanding of 1MW diesel generator.

New Machines List Capacity 15000/day

Running Load Running Load
Machine Qty Amp (Each)
(kW) (Amp)
Yilmak RB 500 2 20 25 40
YILMAK SAMPLE 1 10 6 10
BARREL WASHER LARGE 7 12 52 84
BARREL SAMPLE 7 3 13 21
HYDRO LARGE 5 18 56 90
HYDRO SAMPLE 7 3 13 21
STEAM TUMBLES SEALION
20 5 62 100
(LAUNDRY)
STEAM TUMBLES SEALION
15 5 47 75
(FABRIC)

OZONE SETUP (TWO TMBLES) 1 60 37 60

RO 100 Ton 1 200 125 200

Compressor 160 kW 1 255 159 255
Turbine 45 kw 2 72 90 144
MCS 1800 kg 3 65 121 195
1st Floor 1 300 187 300
Total 993 1595
Efficient Asset Tracking: Motors and VFDs Dataset Creation for
Oracle Database
I created a dataset containing information about all the motors and Variable Frequency Drives
(VFDs) tags, and then the IT team uploaded this dataset to Oracle. Here's a breakdown of the
process:

1. Dataset Creation:
• Scope Definition: Understand the required information for motors and VFDs, such as
model numbers, specifications, installation dates, maintenance history, etc.
• Data Collection: Gather relevant data from various sources, including equipment
manuals, maintenance records, and collaboration with relevant teams.
• Data Structure: Organize the dataset with appropriate columns for each piece of
information, ensuring it's structured and easy to use.
• Data Validation: Verify the accuracy and completeness of the collected data to ensure its
reliability.

2. Dataset Compilation:

• Compile Information: Enter the gathered data into the dataset, associating each data
point with its corresponding motor or VFD tag.
• Unique Identifiers: Ensure each motor and VFD has a unique identifier or tag for easy
reference and retrieval.
• Quality Checks: Conduct quality checks to identify any inconsistencies or errors in the
dataset.
 Figure 5: Data Set

3. Dataset Review and Approval:

• Review with Stakeholders: Share the dataset with relevant stakeholders, such as
maintenance teams or managers, for their review and approval.
• Incorporate Feedback: Incorporate any feedback or additional information provided by
stakeholders.

4. Data Upload to Oracle:

• Collaboration with IT Team: Coordinate with the IT team responsible for Oracle to
understand the data upload process and requirements.
• Data Mapping: Map the dataset columns to the corresponding fields in the Oracle
database.
• File Preparation: Prepare the dataset file in a format compatible with Oracle's data
upload procedures.
5. Oracle Database Upload:
• Data Upload: Provide the prepared dataset file to the IT team for uploading into the
Oracle database.
• Validation: Confirm with the IT team that the data has been successfully uploaded.
• Post-Upload Checks: Conduct post-upload checks to ensure the data in Oracle matches
the original dataset.

6. Documentation:
• Documentation of Processes: Document the processes followed for dataset creation,
compilation, and Oracle upload for future reference.
• User Guidelines: Prepare user guidelines or documentation on how to access and use the
motor and VFD data in Oracle.

7. Follow-up:
• Monitoring: Regularly monitor the data in Oracle to ensure its accuracy and relevance.
• Updates: Update the dataset as needed, especially when there are changes or additions to
the motors or VFDs.
By following these steps, I contributed to the organization's data management and maintenance
processes, providing a reliable source of information about motors and VFDs in the Oracle
database.
Figure 6: ERP (Motor and VFD tagging)