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High Horsepower Master Rebuild Center
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| 27 Nov 2012 |
In February 2012 Cummins Middle East welcomed the completion of the High Horsepower (HHP) Master Rebuild Center (MRC). Ian Norton, HHP Master Rebuild Center Manager, oversaw the establishment of this world-class facility in the Middle East, from planning and research, to staffing and marketing of the HHP MRC.
The center, the first of its kind in the region, aims to cater to rebuilding engines above 19 liters which are most commonly used in commercial marine vessels, prime power generation and mining – where reliability is a must.
“Firstly, we carried out a viability analysis for the HHP rebuild business in the region,” says Norton of the initial planning stage; “then I travelled internationally, benchmarking Cummins’ other HHP MRC facilities, as well as our own engine business manufacturing sites, to ensure we came up with a top-of-the-line design for the CME facility.”
Construction on the Center began in June 2011. Civil engineering works were completed in March 2012.
Being the only Cummins High Horsepower Master Rebuild Center in the region, there were questions as to the functions of the facility. Norton says the HHP MRC is a purpose-built facility dedicated to high quality, high volume rebuilds of Cummins high horsepower engines, certified to Cummins Global Standards, which include:
- Machining to Cummins Global Standards
- Utilization of torqueing tool(s) capable of meeting Cummins Inc. manufacturing and HSE standards
- Use of genuine Cummins new and ReCon parts
- Systematic testing at each phase of production
- Dynamometer testing, including mini patch testing, following HHP new engine testing standards
- A dry-filter paint booth
- Cleaning equipment yielding high quality aesthetic standards after painting
- Lifting and material handling equipment that follows current Cummins safety standards
- ISO 14001 (Environment) and OSHAS 18001 (Safety) Certification
- ISO 9001 Certification (including utilization of SQP process)
Cummins has a large and increasingly growing number of HHP engines in the Middle East, which currently stands at 12,000 units, with an expected annual growth rate of around 10 per cent.
Annually, according to Norton, approximately 12 per cent of Cummins' HHP engines need a rebuild.
Research carried out by CME indicated that the majority of customers strongly prefer a bespoke Cummins rebuild center, offering certified rebuilds.Norton added that “from a Middle East Distribution perspective, the HHP MRC is another facet of our drive towards providing legendary service”.
Dubai was selected as the ideal location for the Middle East’s first HHP MRC for a number of reasons, including the fact that the Cummins Middle East Headquarters is based in Dubai; its world-class logistics; a broad, high-quality supplier base, and a large amount of Cummins Middle East customers’ headquarters being based in Dubai as well.
Accessibility and convenience of the location is also a major advantage of the facility.
Other advantages include:
- customers can conserve their focus for their core business
- reduced equipment “down” time
- customers can avoid additional expenses such as labor, materials, equipment, tools and facilities
- rebuilding a Cummins HHP engine at the Cummins MRC means a longer engine life, lower lifecycle costs and less unscheduled failures
In addition, rebuilds are backed by Cummins Global Distribution channels, using processes that conform to the Cummins Global Manufacturing Standards, which promise higher reliability and one-year unlimited warranty, as per Cummins standard warranty conditions.
The CME HHP MRC is looking at a production capacity of 540 units a year on a single shift pattern, which they hope to achieve within the next three to four years. Norton claims the new facility ties in to two of Cummins’ core values as a company - diversity, in the form of a multinational, multidisciplinary and multi-talented team working together for the success of this new facility, and innovation.
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