INTERNSHIP REPORT
Workshop Motors Process Improvement & Database
I&E DEPARTMENT | ELECTRICAL
MUTAHAR KAMRAN MUGHAL
MENTOR: SHEHERYAR AHMED
Page
1
9th - Sept - 2022
Mutahar Kamran Mughal
Internship Report
Acknowledgement
The internship opportunity I had with Engro Fertilizers Limited Daharki, was a great
chance to further develop my industrial knowledge/skills and professional development.
Therefore, I consider myself a very lucky individual as I was provided with an opportunity
to be a part of this esteem organization. I am also grateful for having a chance to meet such
sublime people and professionals who led me through this internship period.
I would like to exhibit my special thanks to Mr. Ahsan Jawed, Electrical Manager, for
giving me a chance to exercise my knowledge in his department and helping me in my dayto-day activities during my internship period.
I would also like to extend my thanks to Mr. Mutahir Rasool for his constant support and
his extensive knowledge. It was an absolute pleasure to be working with him.
Bearing in mind previously, I would like to take this opportunity and express my deepest
gratitude and special thanks to my mentor, Mr. Sheheryar Ahmed, who took the time to
hear, guide, and teach me and also keep me on the correct path, and allow me to carry out
my internship in the most fruitful way possible.
Page
2
I am very much thankful to Engro Fertilizers Limited Daharki, its management, and
especially the employees of the I&E department for their cordial support during this
internship period.
Mutahar Kamran Mughal
Internship Report
Content:
1. INTRODUCTION………………………………………………………...............4
2. SITES COVERED………………………………………………………………...5
3. ISSUES AND IMPROVEMENTS………………………………………………..6
3.1. IMRPOVEMENTS MADE TO DATABASE……………………………7
3.2. IMROVEMENTS MADE TO WORKFLOW……………………………8
3.2.1. CURRENT WORKFLOW……………………………………9
Page
3
3.2.2. IMPROVED WORKFLOW…………………………………..10
Mutahar Kamran Mughal
Internship Report
Workshop Motors Process Improvement & Database
TASK:
To make workflow improvements and improve the usability of the existing database.
1. INTRODUCTION:
Microsoft Access is a database management system (DBMS) that combines the
relational Microsoft Jet Database Engine with a graphical user interface and
software-development tools.
Tables
•
Quieres
•
Forms
•
Reports
Fig.7.1 Basics of Microsoft Access
Mutahar Kamran Mughal
Internship Report
Page
•
4
The major components of MS Access are as follows:
Easy to create database within lesser time duration. Uses a very comprehensive
programming language, which is made easier, and user friendly.
2. SITES COVERED:










Ammonia-1
Ammonia-2
Ammonia-3
Utility-1
Utility-2
Utility-3
Urea-1
Urea-2
Urea-3
PM&S-1









PM&S-2
PM&S-3
Housing
Offsite-1
Offsite-2
Encop-1
Encop-2
Encop-3
Workshop
3. ISSUES / IMPROVEMENTS:
3.1.

Improvements made to Database:
One of the very first and most important things I was able to do improve were the Data
Validation rules.
Mutahar Kamran Mughal
Internship Report
Page
These data validation rules have been added to critical fields like Serial Numbers and Tag no
Numbers of motors. So, the uniqueness of the above fields can remain. This minimizes false and
5
As we can see from the above images data was being entered in all sorts of format, causing a lot
of inconsistency especially when we wanted to pull the data from the database regarding a
specific motor. We were using ‘-‘ and ‘/’ and other special characters with Tag and Serial
numbers.
inaccurate entries. Moreover, it makes finding the motor and information relating to it much
easier to find and use.

Another important thing that was added was the delete button. Delete button was added
to the motor-hauling and motor-burnout form.
The reason for doing this was that many bogus and duplicate entries were entered in the
database. We can use this button to delete any false entries that were entered by mistake and also
so that the database remains user-friendly, and only provides accurate and useful data.
The delete button was also password protected. As shown in the image below.
Page
This was introduced to prevent unauthorized deletion of records without the knowledge of the
supervisor. Only a select few personnel should be authorized, those who should know the
password.
6

Mutahar Kamran Mughal
Internship Report

The Serial numbers and Tag numbers were made Unique. That means that only one
serial and tag number corresponds to only one motor. Preventing any further duplicate
entries and keeping the database clean. Further making it easier to get accurate useful
motor information. Also saving time. Fetching and processing data becomes easy.

One major problem existing in the database. There were many similar entries persisting
when I started working on this project.
We have 966 entries including similar entries. Running a query to see how many duplicate
entries we have, we came up the to the value of 138 duplicate entries. Getting rid of these
values leaves us with 828, values that we can work with. As shown in the image below.
*My suggestion is that we do the data entries from scratch so that we can ensure no
duplicate values can be entered into the database in the future.*
Implemented the use of Drop-Down menus in different forms. One good example is
the root cause menu. As shown in the image below.
Page
7

Mutahar Kamran Mughal
Internship Report
This was done to prevent free writing of the same root cause in different styles like some
alphabets in upper case and some all lower case or mixed. This was done to create uniformity
and consistency and so that things are easy on the eyes.

Now we can search different motors using the special generated Motor ID that is
generated by the database itself.
This was mainly introduced for those motors that have missing or no Name Plates, hence
allotting them their own serial number using the database generated Motor ID gives them their
own identity making it easier to search them in the database and extract information related to
them. This is particularly helpful when the tag number is missing as well.
New form for New Motor Manufacturer was created so new motors manufacturers
can be added to the list.
Mutahar Kamran Mughal
Internship Report
Page

8
Enter the Serial Number as Follows: SNA*MOTOR ID*
This option has been made available only to make the form user friendly and that we can easily
add any new manufacturer if any easily through a form and then selecting it through the drop
down menu. As shown below.
Implemented new Motor Rewinding and Overhauling Forms. Previously they were
the same form making the forms tedious and difficult for the area technicians to fill.
That is why a lot of inaccurate data was being received and feed into the database.
Both forms were separated so that the process is simplified and documentation is
made easier for technicians in the field and workshop.
Page
9

Mutahar Kamran Mughal
Internship Report

Motor Burnout and Overhauling form now has a Motor ID text box, so now we can
always track / identify the motors by their Special ID numbers as well. Making the
overall usability of the form more user friendly.

Limitation on the Coil Size field in the Motor Data form was removed, from only
numbers to, numbers and ‘/’.
When a motor is being winded, different number of Sets of coils are used. So to express their
size we need multiple values. The ‘/’ helps separate the different sizes of the different coils used
in a specific set.
 Old Stock number for spare motors format changed to a new format so the following
changes were made in accordance with the workshop supervisor.
Page
10
Old format field box is still kept since most of the entries made are in accordance with the old
format. The supervisors should monitor that the new format field is also being filled so that the
database is kept up to date.
Mutahar Kamran Mughal
Internship Report

No-Load Amperes field box has been added so that the technicians always have a
way to compare the No load Amperes when the motor comes in for rewinding and
overhauling. This keeps the process more streamlined.
 Validation rules were also applied on the Date Format field box. Following changes
were made.
As we can see in the images above the date added is an invalid date, as it is exceeding the present
date. The following changes were made to the Motor Rewinding and Overhauling form. The
dates can no longer exceed the present date. This makes the data more accurate and less prone to
errors.
One of the Root causes was updated from electrical issues too Motor winding
burnout.
Page
11

Mutahar Kamran Mughal
Internship Report
3.2.
Improvements made to the Workflow:
 3.2.1. Current Workflow:
Motor burned
out in the area
Technician attended the motor and motor shifted to workshop for rewinding
Notification raised and Initial investigation information filled in and duly signed by area supervisor
in hard copy form
Hard copy handed over to shop technician
Root cause investigation to be filled in by shop’s technician after which, form would to be duly
signed by Workshop supervisor and section head
Motor disassembled and handed over to mechanical shop for balancing. Rewinding would be
done by shop technician
All the data for rewinding to be filled in by Electrical shop technician. All the data for rotor
dimensions to be filled in by mechanical shop technician.
Motor tested in presence on MTS and I&ER then all the test data recorded by shop technician.
Once the form is complete, all the data from the hard copy transferred to data base by I&E office
assistant and hard copy filled in motor overhauling record file.
Page
12
Motor dispatched to area after
pasting Motor Dispatch Card
Mutahar Kamran Mughal
Internship Report

3.2.2. Improved Workflow:
Motor burned
out in the area
Technician attended the motor and motor shifted to workshop for rewinding
Notification raised and Initial investigation information filled in and duly signed by area supervisor
in hard copy form
Hard copy handed over to shop technician
Root cause investigation to be filled in by shop’s technician after which, form would to be duly
signed by Workshop supervisor and section head
Motor disassembled and handed over to mechanical shop for balancing. Rewinding would be
done by shop technician
New Bearing Procedure Proposed, Referenced to WEG’s Bearing Replacement Procedure.
All the data for rewinding to be filled in by Electrical shop technician. All the data for rotor
dimensions to be filled in by mechanical shop technician.
Motor tested in presence on MTS and I&ER then all the test data recorded by shop technician.
Once the form is complete, all the data from the hard copy transferred to data base by I&E office
assistant and hard copy filled in motor overhauling record file.
Page
13
Motor dispatched to area after
pasting Motor Dispatch Card
Mutahar Kamran Mughal
Internship Report
Added a new point in the workflow in accordance with the Bearing Replacement
Procedure proposed by WEG’s.

A Motor winding / Overhauling / Responsibility Checklist was made which has been
implemented to the Rewinding and Overhauling form accordingly in the database.
Page
14

Mutahar Kamran Mughal
Internship Report

One major improvement we can make is introduce a Barcode or QR Code system.
Page
15
ADVANTAGES:
1. This can drastically reduce troubleshooting time.
2. When a motor comes to the workshop for rewinding or overhauling. We don’t need to
waste time inputting data manually.
3. Just scanning the Barcode or QR code can retrieve all the history related to the motor
in play.
4. Thus, reducing a lot of troubleshooting time.
5. As the previous Root cause can help narrow down the problem quickly and
efficitently.
6. Moreover, the database will only be used for one time motor data entry and
corresponding Overhauling and Rewinding data entry.
Mutahar Kamran Mughal
Internship Report