Case Study: Fauji Fertilizer Company achieves faster operator training and reduced unscheduled shutdowns with AVEVA

Operator Training Simulation Solution Strengthens Operator Skills, Improves Safety and More

Fauji Fertilizer Company, one of Pakistan’s largest fertilizer producers, faced the dual challenge of commissioning a new distributed control system (DCS) while rapidly preparing operators for rare emergency scenarios and upcoming workforce turnover. AVEVA provided an Operator Training Simulator (OTS) solution with high‑fidelity process modeling and control-room HMI replication to give both experienced staff and new hires realistic, hands‑on training without risking plant operations.

Using the AVEVA OTS and a “train‑the‑trainer” approach, FFC produced 22 OTS instructors who ran 130 training sessions in the first year and trained 93 managers and staff; training time fell from years to months. Operators now respond more consistently in startups, shutdowns and emergencies, unscheduled shutdowns and unplanned startups have been significantly reduced, and overall plant uptime, safety and operational steadiness have measurably improved under AVEVA’s integrated simulator solution.

Fauji Fertilizer Company

Mubashar M. Butt

Deputy Manager Production