Dubai Cable Company (Pvt) Ltd., (Ducab), the UAE's flagship cable manufacturer is currently undergoing a period of intensive capacity expansion at its massive facility close to Jebel Ali Free Zone.
The last major expansion at Ducab was completed less than two years ago and included the commissioning of a state-of-the-art medium voltage insulation line that has been 100 per cent loaded since being commissioned in June 1999.
Ducab is enjoying a period of robust sales and last year the company received the largest single order in its history when ADWEA (Abu Dhabi Water and Electricity Authority) placed orders for $32 million (Dh120 million) of power cables.
Ducab continues to improve cost efficiencies across its product range and adopts an uncompromising total quality management approach. In 1997, Ducab became the first power cable manufacturer in the world to secure ISO 14001 environmental quality management certification.
In June 2000, Ducab announced outline plans for further plant expansions at a cost of Dh45 million ($12 million) and capacity increases. The installation of a second medium voltage line is almost complete and due for commissioning in June 2001 together with increased capacity for low voltage cables. The size of the overall manufacturing facility has also been extended by some 35 per cent.
The new Powerplus medium voltage line will more than double output capacity for this range of power cables. Other new plant also includes rod breakdown, stranding, sheathing and laying up machines.
A major aspect of the Ducab success story in recent years has been the company's close partnership with ADWEA.
A joint ADWEA/Ducab technical committee has evaluated distribution cable designs and achieved substantial savings through more cost-effective designs for 11 and 33 kV power cables.
Working with ADWEA engineers, Ducab has adopted thinner insulation with improved and specified concentricity, improved short circuit ratings and upgraded the specifications of water-free retardant insulation for 33 kV cables.
The close partnership with ADWEA has also led to greater service provision by Ducab as the requirement for improved jointing procedures in the field was identified. Cables fail only rarely with the primary cause of faults in electrical distribution networks generally associated with joints and terminations.
Ducab is concerned about safety and reliability and committed to raising standards within the electrical supply industry. Ducab established a Jointer Training Academy to train jointers and improve jointing procedures.
Ducab now celebrates 21 years of industrial achievement in the region and is owned by the Governments of Dubai and Abu Dhabi with equal shares of 35 per cent, and the BICC Group of the UK with 30 per cent.
Ducab's product range covers low voltage power cables, control and auxiliary cables, wiring cables, lead sheathed cables as well as Smokemaster LSF cables for projects where safety is paramount. Ducab also produces Powerplus medium voltage cables up to 33kV.
Massive investment in the latest production technology has given Ducab the most advanced cable manufacturing facility in the Middle East and Ducab's aim is to produce electric cables of the highest quality and provide customer service that is unequalled in the Gulf region. Quality and customer service are twin objectives for Ducab.
The definition of quality in Ducab goes far beyond the conformance of product to specified requirements. Ducab is committed to providing the customer with total quality excellence of product and service that fully meets expectations and is superior in value to that which can be obtained elsewhere.
Ducab is certified to ISO 9001 quality management systems as well as ISO 14001 environmental management systems. Ducab's excellence in quality was recognised when the company was awarded the Dubai Quality Award in the very first year of its inception, in 1994, and again in 1998.
Ducab strives for excellence in customer service and has adopted a Value Edge programme which explicitly states the aims and objectives of key aspects of service including response levels to enquiries within 24 hours of receipt.
Ducab also sets itself to reply to all specific enquiries for special deliveries and stock availability within one hour of receipt. The company will even specify a delivery time at the time of placing the order.
Ducab works closely with its major suppliers and its annual copper usage is estimated at 35,000 tonnes per year. As part of its environmental management, Ducab strives to minimise waste and in the case of galvanised steel tape has developed methods to rewind and weld tapes thereby reducing scrap.
The company also works closely with its wooden drum supplier and has developed a returnable system for steel despatch and process drums.
Safety has always been implicit to the culture of the Ducab organisation which received its tenth consecutive gold award for industrial health and safety from RoSPA in the UK. Ducab is also the first company in the Middle East to achieve BS 8800, the British Standard for health and safety management.
