Why a regional controls workshop matters
Across the Middle East, power and industrial operators are modernizing aging control systems while managing tight outage windows, delivery risk, and supply‑chain constraints. GE Vernova’s JAFZA Controls Workshop, located in Dubai’s Jebel Ali Free Zone, addresses these challenges by enabling localized execution, faster turnaround, and predictable delivery for controls modernization projects across the region.
Established in 2015, the JAFZA workshop was created to support controls modernization through local assembly, integration, and testing, helping to reduce dependence on distant manufacturing locations and improving on‑time delivery.
From focused testing to a regional execution hub
Over the past decade, the JAFZA facility has evolved in capability and impact.
“When I joined, the workshop was already known for quality and customer commitment. Since then, its execution capability and regional impact have grown significantly,” says Mathew Pappachan, Supply Chain Leader.
Today, JAFZA operates as a multidisciplinary controls workshop focused on build, configuration, integration, and testing for modernization projects. While engineering design is led by global teams, the JAFZA team ensures high‑quality execution and validation of controls hardware prior to shipment.
Despite operating within a compact footprint, the workshop consistently delivers high output through lean execution, digital planning tools, and standardized processes.
Core workshop capabilities
The JAFZA Controls Workshop supports controls modernization through execution‑focused capabilities, including:
- Control cabinet assembly and wiring
- Retrofit and migration kit assembly for legacy‑to‑Mark VIe / Mark VIeS upgrades
- Factory Acceptance Testing (FAT) for integrated control and safety systems
- Cyber‑ready system preparation, including hardened PC builds and configuration validation
- OTArmor cybersecurity system configuration and testing
Integrated systems tested at JAFZA include turbine control cabinets combined with Mark VIeS safety systems, HMIs, excitation systems, and third‑party interfaces during FAT prior to shipment.
Controls platforms and modernization execution
The JAFZA workshop supports modernization programs based on GE Vernova’s Mark VIe and Mark VIeS control platforms, widely deployed across power generation and industrial applications.
Workshop scope includes assembly and testing of control panels, safety cabinets, annunciators, marshalling cabinets, HMI systems, power supplies, I/O modules, and networking components supporting broader modernization programs.
A key focus is enabling customers to migrate obsolete control systems to the current Mark VIe platform—supporting incremental upgrades, improved cybersecurity readiness, and long‑term platform support.
“Migration kits allow customers to reuse existing cabinets while upgrading internal electronics, helping reduce outage duration, installation complexity, and project risk,” Mathew explains.
Processes that sustain on time delivery
Lead‑time reduction and delivery reliability are critical customer priorities. By localizing assembly and maintaining regional inventories of critical components, the JAFZA workshop helps shorten delivery timelines.
Lean execution practices—visual job tracking, standardized work instructions, 5S, SQDC performance tracking, and continuous improvement—are embedded in daily operations to sustain on‑time delivery, quality, and safety.
Closing
From localized execution and lean manufacturing to controls modernization and FAT, the JAFZA Controls Workshop demonstrates the value of a regional center of excellence focused on delivery reliability.
“When sales, commercial operations, sourcing, project management, engineering, supply chain and services operate together as one team, we can deliver execution excellence more effectively for our customers,” Mathew says.
By combining people, processes, and technology, the JAFZA team continues to help customers modernize assets and build a more reliable and resilient energy future.
Mathew Pappachan
MEIA Supply Chain Operations Leader
With over 21 years of experience in industrial automation and controls in the energy industry, Mathew is the supply chain operations leader of the JAFZA controls workshop.
Ratna Talupula
EMEIA Operations Leader
With over 21 years of experience in electrical and controls in the energy industry, Ratna is the operations leader for the EMEIA region within Control Solutions & Services.
You might be interested in
Learn more about controls service offerings
Contact us
Want to learn more about how our controls workshop delivers high-performance control systems?