Reduce your equipment downtime, operating cost per hour and experience lower cost per ton – with the world class repair and rebuild services at GCPL’s Component Repair Shops.
GCPL Component Repair Shops are equipped to restore engine and drive-train components to factory standards, and offer component repairs and exchange of component assemblies to support quick re-commissioning of without having to wait for the component overhaul to be completed; thereby ensuring lowest cost of operation with highest machine uptime.
Designed for long, hard and reliable service, even the toughest Cat® will eventually wear out. The cost of replacing a complete aggregate can be prohibitive, so rebuilding the Cat machines and components to give a new life at a fraction of the cost works out in favour of the customer.
The 50,000 sqft, state-of-the-art Component Rebuild Centre (CRC) at Asansol is dedicated to doing just this. Asansol is very uniquely placed within the mineral rich & mining areas of eastern India. The CRC is equipped to test and rebuild all major components as well as machines of the equipment Caterpillar produces today, and is designed to restore engine and drive-train components to factory standards, thereby meeting the world-class Caterpillar benchmark of safety, quality and contamination standards. Pressurised ventilator keep dust away from assembly area to maintain contamination free environment.
CRC offers its customers a clear differentiating experience for their service and maintenance needs with high precision inspection machines like Serdi pressure tester, Magnaflux crack detector and with various salvage options for reusability of high value components. This facility is also equipped with Dynamometer capable of testing 200 – 3,600 HP engine, as well as Transmissions test bench. This complete facility is a nerve centre for the Maintenance & Repair Contract (MARC) projects to meet their schedule repair & maintenance need. A large parts warehouse supports the operation by making the parts readily available.
The CRC also provides exchange of component assemblies to support quick re-commissioning of the machine without waiting for the component overhaul to be completed, ensuring the lowest cost of operation with highest machine uptime.
Machine repair initiative substantially reduces capital investment while achieving the same level of production. The other advantage is that it effectively addresses the demand-supply gaps.
The CRC provides customers with the quality, performance and reliability that is expected from Cat, along with cost savings of up to 60% when compared to the cost of a new components.
Our technicians are experts in component rebuild, from larger projects such as whole machines to smaller components. All are Cat trained, fully skilled engineers so customers can put their trust in the breadth of knowledge and expertise.
When downtime is critical then the off-the-shelf service exchange components and remanufactured engines can minimise the disruption to the operation.
The CRC offers rapid turnaround times and also provides the convenience of collecting and returning the unit to the local branch.
The CRC workshop is one of the few facilities to be granted a Caterpillar Five Star contamination control rating. Contamination control is therefore an essential element of maintenance practices to extend the life of the component.
We have successfully commissioned and completed repair jobs of VOLVO Dump body & Hydraulic Cylinder. This low cost solution and satisfactory performance have resulted in repeat orders and have opened up new arenas for service revenue wherein CRC can undertake repair / rebuild of other makes as well.
The initiatives that started from last year have fetched an additional service revenue of Rs.60 lacs from a single customer with a potential to grow in multifold
Equipped with sophisticated instruments like Viscometer, Particle analyser, ICP, STIR etc., the SOS lab gives an unique edge over competition. All kinds of lubricants being used on earth moving machines can be tested and analysed in this lab. Timely & correct prediction of component health through oil analysis is the major strength of this lab. Systematic & trend analysis done by this lab prevent failures thus reducing machine downtime and leading to savings for customers. This facility also works as a major support centre for our MARC projects by providing correct trend analysis of component health.
To meet with increasing demand, upgradation of this lab is planned in this year. With addition of instruments like Viscometer and commencement of second shift operation, our SOS lab would be ready to process 50,000 samples annually.
The Technician Development and Assessment Centre at Asansol, set up in the same premises as the CRC, has been the GCPL Learning Centre since 2009. The training facility houses classrooms equipped with computers, Hydraulic and Electrical Simulators, Electronic Engine Simulators, cut models and other training aids. To carry out on the iron training, the centre is armed with machines, engines, transmissions, pumps, valves, differentials and other components. Resources includes modern training Infrastructure including engine & transmission bays, material handling equipment, standard and special tools, parts washer, surface table, work bench, turning tools etc.
At GCPL, highest priority rests on capability development and translating the learning in the field towards benefit of the customer and organization. In alignment to the Management focus, Training Department has adapted blended learning module comprising Interactive Distance Learning (IDL,) Instructor Led Training (ILT), Web Based Training (WBT), On the Iron Training and Field Training. The Technician Development and Assessment Centre in Asansol is geared up to provide service and sales training under the blended learning methodology in planned & structured manner based on the skill gap analysis / sales competency assessment.
The state of art training facility has been one of the pillars in achieving the Service Training Excellence Accreditation Award from Caterpillar.