Facility Development – Supporting Offshore Wind Generators – PPI Engineering Ltd.
Company Information
PPI Engineering Ltd (PPI) offers world-class expertise in designing, supplying, and supporting large motors and generators. Serving power, oil & gas, renewables, and mining sectors, PPI provides full service for rotating equipment, backed by a skilled team with original equipment manufacturer (OEM) experience.
Project Overview
PPI Engineering Ltd (PPI) designs, supplies, and supports large motors and generators for industries including power, oil & gas, renewables, and mining.
This project focuses on developing a dedicated generator repair and manufacturing facility in East Anglia to support the offshore wind sector. The aim is to create a state-of-the-art facility that can repair, replace, and improve wind farm generators, helping reduce downtime and increase reliability.
This is a real engineering and production planning project that combines process development, equipment selection, layout design, and cost analysis.
Project Aim
To design and plan a new generator repair and manufacturing facility that increases PPI’s capability to support offshore wind farms, including processes, equipment, layout, and costings.
Key Research Questions
• What processes are required to repair and replace wind farm generators?
• What equipment is needed to support these processes?
• What are the current gaps in PPI’s existing processes and facilities?
• How can lean manufacturing and process flow improve efficiency?
• How can the facility layout maximise throughput and reduce set-up time?
• What would the total equipment investment cost be?
What You Will Do
• Review and develop repair processes for wind farm generators
• Carry out a gap analysis comparing existing and required capabilities
• Research market demand from OEMs (Original Equipment Manufacturers)
• Identify and source suitable equipment
• Create a complete equipment list with costings
• Design a process map showing how work flows through the facility
• Develop a facility layout showing equipment placement
• Apply lean manufacturing principles to improve efficiency
• Consider processing set-up times to maximise throughput
• Work with the production team to review and finalise the design
Science, Engineering and Technical Understanding
• Learning how large electrical rotating machines are repaired and maintained
• Understanding generator obsolescence and lifecycle management
• Applying lean manufacturing and process flow principles
• Evaluating production efficiency and operational performance
• Linking equipment selection to technical requirements
Planning and Organisation
You will:
• Break the project into stages (process review, gap analysis, equipment research, layout design, costing)
• Organise technical and cost data clearly
• Justify decisions using engineering reasoning
• Work independently while engaging with the production team
Skills Developed
• Engineering process development
• Factory layout design
• Procurement and cost analysis
• Production management
• Project planning and organisation
• Communication and presentation skills
Final Outputs
• A written report
• A complete list of required equipment with costings
• A process map for generator repair and replacement
• A facility layout design showing equipment installation
• A presentation outlining increased capability and recommendations
Reflection and Evaluation
Your report may include:
• What you learned about generator repair and manufacturing processes
• Key challenges in designing a new facility
• How your proposed layout improves efficiency and capability
• What you would refine or develop further
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