GE Vernova’s JAFZA Controls Workshop: A regional hub for modernization, reliability, and lifecycle support
In Dubai’s Jebel Ali Free Zone, GE Vernova operates a controls workshop that supports power generation and industrial customers across the Middle East, North Africa, India, APAC, and beyond. Since its establishment in 2015, the JAFZA Controls Workshop has evolved from a focused assembly and testing operation into a regional hub for controls modernization, lifecycle support, and engineered solutions.
The workshop is part of GE Vernova’s global network supporting critical energy infrastructure and plays an important role in helping customers maintain reliability, modernize aging assets, and prepare for future operational needs.
Leadership and mission
The JAFZA Controls Workshop is supported by a cross‑functional team spanning supply chain, planning, logistics, manufacturing, and testing. Together, the team manages material flow, supplier coordination, and execution support for Services projects across the region.
The workshop delivers a wide range of controls solutions—from individual panels and electronic assemblies to complex, integrated systems—helping ensure materials and components are available when needed so projects can move forward on schedule.
Evolution into a regional center of excellence
Over the past decade, the JAFZA facility has steadily expanded its capabilities.
“When I joined, the workshop was already known for quality and customer commitment. Since then, its scale, scope, and regional impact have grown significantly,” says Mathew Pappachan, Supply Chain Director.
Today, JAFZA operates as a multi‑disciplinary workshop supporting assembly, testing, upgrades, and lifecycle activities for regional customers. Despite operating within a compact footprint, the team consistently delivers high output through lean practices, digital planning tools, and continuous improvement.
The workshop supports:
- Control cabinet assembly
- Retrofit and upgrade kits
- Factory Acceptance Testing (FAT)
- Cybersecurity preparation and system hardening activities
- Obsolescence management
- Lean manufacturing for repeatable assemblies
Digitization plays a central role, with modern planning tools, real‑time material visibility, and data‑driven scheduling helping the team respond to changing customer and supply‑chain conditions. Facility layouts for assembly, testing, packing, and storage are continuously refined to improve efficiency and throughput.
Collaboration across GE Vernova’s global network
Although based in Dubai, the JAFZA Controls Workshop operates as part of GE Vernova’s global ecosystem.
Engineering teams in the US and Europe collaborate on specifications and standards, while global sourcing teams help secure critical components. Additional GE Vernova facilities in regions such as India, Hungary, and the US provide supplementary manufacturing and engineering support when needed.
This global coordination helps balance workloads, manage risk, and align quality and safety standards, while enabling regional field teams to access expedited parts, quick‑turn assemblies, and outage support.
Systems expertise and modernization capabilities
The JAFZA workshop supports GE Vernova’s Mark VIe and Mark VIeS control systems, which are widely deployed across power generation and industrial applications in the region.
Work scope includes control panels, safety components, annunciator panels, marshalling cabinets, HMI systems, power supplies, I/O modules, networking components, and engineered replacement kits that feed into larger modernization programs.
A significant portion of activity is driven by obsolescence management. Many regional assets continue to operate well beyond their original design life, and controls modernization helps customers transition from legacy platforms to current, supported systems.
“Migration kits allow customers to reuse existing cabinets while upgrading internal electronics, helping reduce outage duration, installation complexity, and project risk,” Mathew explains.
Lead times, supply chain strategy, and lean execution
Lead time reduction is a key customer priority. By localizing assembly and maintaining regional inventories of critical components, the JAFZA team helps shorten delivery timelines compared to sourcing from distant locations.
Lean principles are embedded in daily operations, including:
- Visual management to track job status and material readiness
- Standardized work instructions to support consistency and quality
- 5S workplace organization to improve efficiency and safety
- Safety, quality, delivery, and cost (SQDC) tracking to enable early issue identification
- Regular Kaizen activities and Gemba walks to drive continuous improvement
Process improvements such as optimized shop layouts and automated cable preparation have improved efficiency while helping reduce the risk of errors during assembly and testing.
Cybersecurity preparation and factory acceptance testing
Cybersecurity considerations are increasingly important for modern control systems. While certain specialized cybersecurity solutions are produced at other GE Vernova locations, the JAFZA workshop supports regional projects through activities such as hardened PC preparation, configuration verification, and system readiness checks aligned with applicable requirements.
Factory Acceptance Testing is performed by integrating control cabinets with HMIs, protection systems, exciters, and third‑party interfaces where required. Customers can participate in FAT activities remotely, allowing them to witness testing, review simulations, and confirm system behavior prior to shipment.
These practices help reduce onsite risk and support smoother commissioning.
Safety culture and workforce capability
Safety is foundational to JAFZA’s operations. Technicians work with high‑voltage systems and heavy equipment, supported by structured safety processes, PPE requirements, regular briefings, and digital reporting tools for safety and quality observations.
Continuous safety improvements include enhanced lighting, ergonomic tooling, and optimized material‑handling solutions. Over time, the facility has maintained a strong safety record supported by proactive reporting and rapid issue resolution.
The team’s experience and technical depth are critical to the workshop’s success.
“Our people care deeply about quality, safety, and customer outcomes. That commitment is what enables consistent performance under demanding conditions.”
Supporting customers through complex projects
The JAFZA Controls Workshop supports a wide range of complex regional projects across power and industrial sectors, including integrated control systems that interface with drives, protection systems, and third‑party equipment.
Close coordination with engineering teams, flexible production planning, and batch execution strategies help manage dependencies on drawings, material availability, and customer schedules. When needed, flexible work arrangements help maintain progress while upholding quality and safety standards.
Enabling modernization and the energy transition
Controls upgrades are often a first step in broader modernization programs. By transitioning to current control platforms, customers can improve reliability and prepare assets for evolving operational and regulatory requirements.
Local execution helps reduce project complexity and timelines, supporting customers as they plan future upgrades and long‑term asset strategies.
Looking ahead
The JAFZA Controls Workshop continues to evolve, with a focus on automation, expanded testing capabilities, increased localization, and stronger digital tools.
“We’re preparing for the next generation of control systems, enhanced diagnostics, and more robust lifecycle models. It’s rewarding to see how this team supports customers across the region.”
In closing
From lean execution and digital tools to modernization and cybersecurity preparation, the JAFZA Controls Workshop demonstrates the value of a regional center of excellence.
“When sales, engineering, sourcing, project management, 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 helps customers modernize assets, manage risk, and plan for a more 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.
Ratma 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.
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