QUALITY PLAN POWER TRANSFORMERS MANUFACTURING
QUALITY PLANPOWER TRANSFORMERS MANUFACTURINGCUSTOMER: SIDOR C.A.PROJECT: POWER TRANSFORMERS FOR R5 SUBSTATION ENLARGEMENT
Job Quality Assurance PlanABB TransformersPereira
STRATEGIC FORMERSERSSUPPORT MNGMNT.INFORMATIONSYSTEMSMAINTENANCE &GENERALSERVICESFINANCIALCONTROL* Mutual InteractionCOMMUNITYSUPPLIERSTRANSFORMER TESTS & OIL ANALYSIS
Matrix SGIWastedChemical Prod.Chemical Prod.F01- MGIPTG001Code:Critical Com.Legal Reg.Enviromental AspectsDangers and RisksManagement Prog.Management ToolsIntegral Quality ManagementLEADERIntegral Quality ManagerOBJECTIVETo plan and to implement the tools of the System of Integral Management of the PT Division, so that both the operation and the control of the Processes of the Mgt. System are effective.SUPPLIERSUBPROCESSINPUTPARTICULAR ACTIVITIESDOCUMENTMeasurement and MonitoringRESPONSIBLEOUTPUTSCustomerManager of PTQQITScope of the Mgt. SystemProcess mapProgram of ManagementGraphic of Central ControlMatrix of Environmental AspectsMatrix of Dangers and RisksMatrix of Legal RequisitesMatrix of Administration of ChangesCOABBPT DivisionInterested partiesRecords of Operational ControlQuality recordsRecord of Evaluation of SimulationsEquipments and devices of measurement andmonitoring calibrated / verifiedRecordsPT DivisionInterested partiesCertifier EntityCustomersCIDETManager of PTQAssistants of PTQUpdated Matrix of Legal RequisitesSupports of Legal FulfillmentRecordsPT DivisionInterested partiesAuditorsCertifier EntityManager of PTQManager of PTHCompetent and Careful PersonnelMinutes of the QITPlans of ActionRecords of Continuous ImprovementQITManager of PTQInternal auditorsAudited PersonsPlans of Actions of ImprovementRecordsManagerial report of AuditsCertificates of Mgt. SystemTo define and to update the scope of the System of ManagementTo define and to update the Processes of the System of Management, its sequenceand interactionActivities of the OrganizationChanges to the New Processesor Modifications of the RequisitesPT DivisionInterested partiesPlanning of the Mgt. SystemTo lead the definition of the Programs and Indicators of the System of ManagementTo give support in the update of Aspects and Environmental Impacts and Dangersand RisksTo define and to communicate practices for the Operational Environmental Controland of OHS for the processes, suppliers and contractorsMGIPTG001NTC ISO 9001:2000NTC ISO 14001:2004NTC OHSAS 18001:2000NEZCP061NEZCP045NEZCP046NEZCP060To identify and access to Legal Requisites and other acquired requisitesTo lead the planning of changes that affect the System of ManagementMgt. System ProcessesCustomersMgt. System ProcessesInterested partiesResults of verifications of OperationalControlPrevious evaluationsCommunications of Interested PartiesLegal conformityActivities of the ProcessesOperational ControlsPractices of response beforeEmergenciesResidues of the ProcessesInformation of Security of ChemicalProductsEquipments of following up andmeasurement (It includes softwarewhen necessary)Operational control and Response before EmergenciesTo identify and to plan the response to potential situations of accidents andemergencies, and to prepare and to mitigate the possible illnesses that areassociatedTo carry out activities of verification of the operational controls defined at theenvironmental level and OHSTo carry out the external management of the residuesTo take care of the minor injuriesTo support technically the Processes of ManufactureTo carry out periodic tests to the procedures of preparation and response beforeemergenciesTo prepare and to execute Programs of calibration / verification (including softwarewhen necessary)ITPTQ001 - 002PAPTQ006 - 007 - 008 - 009 - 010PAPTH002 - 003Manager of PTQPAZCC022Assistants of PTQPAZCH015 - 016Process managersNEZCP063 - 064 - 065Technician Laboratory of OilsITPTQ040 - 041 - PTQ005VisitantsPAPTQ013Engineer Room of TestsPAPTQ027Users of equipments /PAPTQ028devicesITPTQ006 - 008ITPTQ010ITPTQ015ITPTQ035ITPTQ037 - 039To update and to communicate the Legal Requisites applicable to the activities,products and services carried out and given by the OrganizationTo evaluate periodically the fulfillment of the Legal Requisites and others applicable,and to keep records of this evaluationNEZCP046Mgt. System ProcessesUsers of Mgt. SystemAgenda QITRequisites of Mgt. SystemContract with Certifier entityReports of previous AuditsIndicators of managementTo keep the program: School of the QualityQuality SchoolBA PTPR 1LAA000022To plan and to carry out the Audits of the Mgt. SystemMANAGEMENT OF RESOURCESRESOURCES OF INFRASTRUCTUREHUMAN RESOURCESPTQ Manager (Representative of the Direction for Mgt. System) Equipped officesQIT/Managing BoardsComputing EquipmentsAssistants of Integral QualityInformation Technology Resources (Intranet, internet, databases: SSA, CCRP, Borwin, CRS)Internal auditorsBrigade of SecurityRoom of MetrologyCoordinators of EvacuationRoom of conferences with audio-visual aids (video beam, VHS, TV and projector)OHS committeeBrigade LocationEquipped ClassroomsNursing stationPT DivisionTo coordinate the activities of Continuous Improvement and QITAuditsMgt. System ProcessesProcess of Improvementof the Integral QualityTo manage the Legal Fulfillment with the interested PartiesNEZCP026NTC ISO 9001:2000NTC ISO 14001:2004NTC OHSAS 18001:2000General managerCertifier EntityProcesses of Mgt. SystemInterested PartiesQIT
Matrix SGIRemaindersRemaindersCode:Chemical Prod.Critical Com.Legal Reg.Enviromental Asp.Dangers and RisksManagement Prog.Management ToolsMeasurement and MonitoringMeasurement and MonitoringF01- MGIPTG001EngineeringLEADERManager of EngineeringOBJECTIVETo define and to plan the activities that allow to obtain designs that meet the requisites agreed in the contract and to achieve their ratification and the later satisfaction of the clients, at the same time the costs ofengineering and materials foreseen in the selling are met, and also the technical requisites of the product are met.INPUTRecord Meeting SUMPlan of InvoicingTechnical TYDOCUMENTSTo prepare a program of EngineeringTo study Technical UTPUTCLIENTManager of EngineeringElectrical and MechanicalDesignersProgram of EngineeringRecords of Order ClearingPTODesigners of OffersTechnical OfferPTMCards of ManufacturePlansElectrical designStructure of MaterialsData for TestsTechnical SupportPTDPTPPTOMechanical DesignRoom for TestsPlans of ManufactureTechnical SupportPTDPTPPTONew DesignsPTPPTDTo review or to perform Check ListPTMPTEBA PTPRPTMPTEBA PTPRElectrical DesignTechnical normsTechnical specifications of the ClientPrice DatabaseTechnical instructions of BATechnical specifications of the ClientTechnical and Commercial offerTechnical normsTechnical instructions of BATechnical specifications of the ClientTechnical and Commercial offerTechnical normsTechnical instructions of BAElectrical DesignMechanical design forproductionPTEPTMPTSBAElectrical design forDesign for OffersproductionTo do Order ClearingTo prepare a Pre-designITPTE001ITPTE010ITPTE011To do a Technical OfferTo draw up electrical designTo do a Structure in BaaNITPTE002 - ITPTE009Electrical DesignersITPTE002 - ITPTE009Mechanical DesignersPAPTE004PAPTE002Manager of EngineeringElectrical and MechanicalDesignersTo carry out Cards of ManufactureTo prepare information for testsTo carry out a design of Active PartTo carry out a design of assemble,connections y cubing.To carry out a design of isolations (onlyTrafoStar)To carry out Plans for approval (if it isneeded by the client)To carry out external designPTO,PTQPTDPTPElectrical and MechanicalDesignersRequests of Changes of DesignReview and Controlof ChangesTo do a Structure in BaaNTo review, to verify and to validate theElectrical and/or Mechanical DesignTo control changes of Electrical and/orMechanical designMANAGEMENT OF RESOURCESHUMANSINFRASTRUCTUREManager of EngineeringEquipped officesElectrical Design EngineerComputing Equipment (computers, printer and plotter)Mechanical Design EngineerInformation technology resources (Intranet, Internet, software of design, database BA)
Matrix SGIChemical Prod.Critical Com.Critical Com.F01- MGIPTG001Legal Reg.PROCESSPower TransformersLEADERProduction ManagerOBJECTIVETo plan and to carry out the production of the Power transformers, under controlled conditions that allow the fulfillment of the requisites of the Product and the OrganizationSUPPLIERINPUTPTPBA PTPRPTQPTEPTOProduct in ProcessCriteria of AcceptanceSigma CardsCards of Program of ManufacturePlans / designsGeneral Schedule Macro planningEnviromental Asp.Dangers and RisksRESPONSIBLEOUTPUTCUSTOMERTo inspect and to test the product inprocessPAPTP001,PAPTQ001,ITPTP016,Supervisor Control ofProcesses of PTPQuality records (Sigma Cards)Sub process of Room er and Operators ofWindingsBlock of WindingsSub process ofAssembling andConnectionsITPTP003ITPTP008Leader and Operators ofAssemblingVerticalized CoreSub process ofAssembling andConnectionsITPTP026ITPTP009ITPTP044Leader and Operators ofAssemblingActive part assembled and connectedSub process of ,ITPTP042Leader and Operators ofAssemblingTransformer finished and ready fortestsSub process of Room 6 - ITPTQ022ITPTQ032Engineer of Room of TestsTransformer released by Room ofTests, Protocols of Tests, Minutes ofControlling, Reports of Feedback tothe DesignPTP, PTO,PTEITPTP038ITPTP045Leader and Operators ofAssembling and ShippingCore ManufactureSub processes of Assemble andConnections and WarehouseActive connected partTankAccessoriesProcessed and proved oilPlans/DesignsTo windTo dry and to press WindingsTo separate plates by groupsTo prepare table for stackingTo stack, press and put vertically the coresTo strain or to apply AsecondActive Part AssemblyPTSSub processes of Cores,Windings and WarehouseTo paper conductorsTo dry and to press WindingsTanking and Final AssemblyWindingsCoreClampsSwitchPlans/DesignsTo mount Windings in coreTo close top yokeTo connect Active PartTo prepare cubingTo dry Active PartTo tight again and to cubeTo mount accessoriesTo prove preliminarily the AirtightnessTo try and to analyze the Dielectric OilTo do vacuum and to fill with oilTo rest and To impregnateTo place control wiringFinal TestTo Carry out electrical TestsTransformer for testsGeneral information of TestsPTPPTETo test control wiringReadying andOperative ShippingTo prepare protocols of testsSub process of Room of Tests Released Transformer for ShipmentPTSPackagingPTEPacking ListTo test airtightness, to dismantle externalaccessories, to do identification andmarking, to coordinate their packagingTo register consumptions in BaaN and todo entry to WarehouseMANAGEMENT OF RESOURCESHUMANSManager of ProductionINFRASTRUCTUREPlant of manufacture of Power transformersPlanner of ProductionEquipped officesSupervisor of ProductionComputing equipmentAssistant of WindingsInformation technology resources (Intranet, Internet, databases, BaaN System)Recursos informáticos (Intranet,Internet, Bases de Datos, Sistema BaaN)Room of Tests for transformers of Potency and Laboratory of OilsAssistant Assembly WindingsTeams of safety and personal protectionPaper OperatorEquipment for the handling of heavy loadsEquipment of inspection, such as micrometers, gauges and others,related to the technical instructionsOperator of InsulationsLeader of WindingsOperator WindingsMachinery and equipment of plant to manufacture the product in accordance withthe provisions of the instructions of BA and the Production Manuals ofLDT and TrafoStarOperator Assembly WindingsFinancial resourcesAssistant of AssemblingAssistant of MaterialsAssembling LeaderOperator of OilsWiring OperatorOperator of ConnectionsOperator of ShipmentsOperator of Cubing and Final AssemblyOperator of Cores and Active PartChief of Room of TestsOperator Laboratory PTPTechnician of Laboratory of OilsMesasurement and MonitoringDOCUMENTSWinding manufactureStandard and customizedmaterials, approved, and minor rawmaterialsManagment ToolsPARTICULAR ACTIVITIESTo prepare isolationsWarehouseManagment Prog.SUBPWasteProcess controlCode:Transformer ready for shippingRegistration in BaaNPTO
Integral Quality Organization ChartGeneral ManagementQITManagers TeamQHSE ManagementInternal AuditorsQHSE - BASCQualityH&SEnvironmentalBASCTest ProcessesCarlos OssaM. Marín – L. MontoyaPaula MesaSamuel ZuluágaJCV – JM - HVQuality SchoolInstructorsSafety BrigadeSPT TREvacuationCoordinatorsDTR TROHS AdvisorOil AnalysisABB
A little of history (Integral Quality milestones)Ø1990: ABB Group arrives to Pereira s factory through a global acquisition ofWestinghouse T&D segmentØ1996: Quality Management System is certified with ISO 9001 by BVQiØ1999: Environmental Management System is certified with ISO 14001 by BVQiØ2002: Philip Crosby s Quality Improvement Process is implementedØQIT: Quality Improvement Team is established with the local TopManagementØQS: Quality School program is launched to give all people trainin inQuality issues, technical competence and to encourage their QualityAwarenessØ2003: Six Sigma tool is implemented for TrafoStar power transformersØ2005: Occupational Health and Safety Management System is certified withOHSAS 18001 and the 3 Management Systems are integrated in QHSEØ2006: BASC Managemen System is certified by the WBO (Business Alliancefor Secure Commerce)
Last 10 years improvement profile and our VISIONσ65QIP2ISO 140013ISO 90014BASCOHSAS 18001 SGI QHSEWorld Class Manufacturer11996199920022005 2006τ2009
We have a great VISIONØIn 2009 ABB Pereira will be a World ClassManufacturing plantØHappy people doing well their workGeneral view of windings shop in ChonqingAll employees celebration
The Integral Quality wayZero FailuresZero ImpactsZero AccidentsTPT & TTPTreductionOn Time DeliveryCustomer SatisfiedCOPQ’s reductionCash FlowA good present forEverybody!Stability & SafelabolGreater EBITMore ordersBest prices
Our Integral Policy show us the way
QHSE and BASC Policy (Translation)Do well our work since first time to get Customer'sSatisfaction by means of Quality Products and QualityServices delivered on time, producing the budgetedprofitability.To get this, our commitment is:ØPromote people's Competence and Awareness as our greatest assetØTo rise the life's quality of our employees by means of the continuousimprovement in H&S issuesØReduce waste generation and natural resources consumption in ourprocessesØImprove continuously our Processes efficacyØPrevent illegal practices in our processes (terrorism, illegal trade,drugs traffic, etc.)ØFulfill all the legal requirements in our processes
Our Zero Defects ObjectivesQHSE ObjectivesZero COPQQuality ISO 9001Environ. ISO 14001100% OTDZero Oil ADORESCONSERVADORZero TestFailures100% CustomerSatisfactionOHSAS 18001Zero Lost DayIncidentsBASCZero ElectricalEnergy WasteZerocontaminationZD does not mean that we will not have failures, it meansthat we will not be happy with any failure!ABB
The Quality Strategy1.2.Philip Crosby s – QIT – QualityImprovement Process:nQuality SchoolnQuality Improment TeamnZero defects philosophyIntegration QHSE BASCPhilip Crosby
esinc2002Quality Improvement Process launching
esinc2002Quality Improvement Process launchingQuality School s principle:“The Competence and Consciousness of our employeesare our greatest assets”.BA PPTR Mnger.
esinc2002Quality School launchingQuality Class Room
esinc2002Quality School strucutreCourse for Managers – QIT(12 Hours in one weekend)Course to get internal Quality InstructorsCourse for White collars(25 Hours in 10 weeks)uQuality EducationSystem (QES)Each Improvement Project1000 USD SavingsCourse for Blue collars(15 Hours in 6 weeks)Each Improvement Project1000 USD SavingsuQuality Throughout Work Team (QTWT)QS: Every body talking same languaje: Quality!
esinc2002Quality Improvement TeamEMC:ü General Managerü Quality Managerü Controllerü Logistic Managerü Human Resource Managerü Engineering Managerü Production Managerü Marketing Managerü Supply Managerü Order Handling ManagerThe QIT in 2002. Today it has 10 membersand they meet each two weeks with thefollowing agenda
Quality Improvement TeamBasic Cyclic Agenda1st MeetingImprovementProjects2nd Meeting3th Meeting4th MeetingCCRPQualityPerformanceIndexBalance ScoreCardManagmentSystems IntegrationQuality ActionPlans on goingTraining Program& Quality SchoolMetalshopsuppliesFollow up toQHSE ObjectivesEnvironmentalManagmentSystem –NCR PowerTransformers5S andSix Sigma &dpmo’sAudit ReportsNCR DistributionTransformers- QS -HousekeepingIn each session at least three of this topics are reviewedandCustomerSatisfactionFollow upOHSAS 18001
QHSE BASC IntegrationAdvantages we have from the QHSE integration1.People develope a holisitic processes approach2.One integral Policy easier to implement and follow3.Less number of internal and external audits, we pass from 12 to 4 per year4.One integral Manager s review5.Integral operational control for Environmental and OHS systems6.One integral induction program for new employees7.More efficient use of IS resources and leaner documentation8.Less number of registers9.Prevention of lawful nonconformity10. One integral Manual book (it is an interactive document)
QHSE BASC CertificationsBASCOHSAS 18001since 2005ISO 14001ISO 9001since 1996since 1999since 2006
Certifies are not enough to be World VIORSVALUESBELIEFSWorld ClassFocusResourcesISO 9001, ISO 14001,OHSAS 18001, BASC, etcMP, TI, Manuals, etc.
QHSE Management evolutionBy Abraham Maslow (1908 – 1970)
The IntegralEmployeeknows, wantsand has willpower!
Next stepsDESCRIPTIONTest Rooms accreditation acc. to ISO – IEC 17025DATEJune /08Implement Social Responsibility Management System December /08acc. to SA 8000 StandardIntegrate QHSE BASC SRDecember /08Columbian Quality Management AwardDecember /08Iberoamerican Quality Management AwardDecember /09
QUALITY PLAN POWER TRANSFORMERS MANUFACTURING CUSTOMER: SIDOR C.A. PROJECT: POWER TRANSFORMERS FOR R5 SUBSTATION ENLARGEMENT . Job Quality Assurance Plan ABB Transformers Pereira. C U S T O M E R S . Supervisor Control of Processes of PTP Quality records (Sigma Cards) Sub process of Room of Tests To prepare isolations To paper conductors To wind
applications including generator step-up (GSU) transformers, substation step-down transformers, auto transformers, HVDC converter transformers, rectifier transformers, arc furnace transformers, railway traction transformers, shunt reactors, phase shifting transformers and r
2.5 MVA and a voltage up to 36 kV are referred to as distribution transformers; all transformers of higher ratings are classified as power transformers. 0.05-2.5 2.5-3000 .10-20 36 36-1500 36 Rated power Max. operating voltage [MVA] [kV] Oil distribution transformers GEAFOL-cast-resin transformers Power transformers 5/13- 5 .
7.8 Distribution transformers 707 7.9 Scott and Le Blanc connected transformers 729 7.10 Rectifier transformers 736 7.11 AC arc furnace transformers 739 7.12 Traction transformers 745 7.13 Generator neutral earthing transformers 750 7.14 Transformers for electrostatic precipitators 756 7.15 Series reactors 758 8 Transformer enquiries and .
cation and for the testing of the transformers. – IEC 61378-1 (ed. 2.0): 2011, converter transformers, Part 1, Transformers for industrial applications – IEC 60076 series for power transformers and IEC 60076-11 for dry-type transformers – IEEE Std, C57.18.10-1998, IEEE Standard Practices and Requirements for Semiconductor Power Rectifier
Ex. 8-2 Transformers in Parallel . 347 Connecting transformers in parallel to supply greater load power. Measuring the efficiency of parallel-connected transformers. Ex. 8-3 Distribution Transformers . 355 Introduction to basic characteristics of distribution transformers.
- IEC 61558 – Dry Power Transformers 1.3. Construction This dry type transformer is normally produced according to standards mentioned above. Upon request transformers can be manufactured according to other standards (e.g. standards on ship transformers, isolation transformers for medical use and protection transformers.
Transformers (Dry-Type). CSA C9-M1981: Dry-Type Transformers. CSA C22.2 No. 66: Specialty Transformers. CSA 802-94: Maximum Losses for Distribution, Power and Dry-Type Transformers. NEMA TP-2: Standard Test Method for Measuring the Energy Consumption of Distribution Transformers. NEMA TP-3 Catalogue Product Name UL Standard 1 UL/cUL File Number .
defines adventure tourism as a trip that includes at least two of the following three elements: physical activity, natural environment and cultural immersion. It’s wild and it’s mild The survey also asked respondents to define the most adventurous activity undertaken on holiday. For some people, simply going overseas was their greatest adventure whilst others mentioned camping in the .
