abb power transformers

8/3/2019 ABB Power Transformers

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QUALITY PLAN

POWER TRANSFORMERS MANUFACTURIN


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Job Quality Assurance Plan

ABB Transformers

Pereira


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MARKETING

&

SALES

ENGINEERING

DISTRIBUTION

TRANSFORMERS

POWER

TRANSFORMERS

LOGISTIC

C

U

S

T

O

M

E

R

S

STRATEGIC MANAGEMENT

TRANSFORMER TESTS & OIL ANALYSIS


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Code: F01- MGIPTG001

PROCESS

LEADER

OBJECTIVE

SUPPLIER INPUTSUB

PARTICULAR ACTIVITIES DOCUMENT RESPONSIBLE OUTPUTS Customer

To define and to update the scope of the System of Management

To define and to update the Processes of the System of Management, its sequence

and interaction

To lead the definition of the Programs and Indicators of the System of Management

To give support in the update of Aspects and Environmental Impacts and Dangers

and Risks

To define and to communicate practices for the Operational Environmental Control

and of OHS for the processes, suppliers and contractors

To identify and access to Legal Requisites and other acquired requisites

To lead the planning of changes that affect the System of Management

To identify and to plan the response to potential situations of accidents and

emergencies, and to prepare and to mitigate the possible illnesses that are

associated

To carry out activities of verification of the operational controls defined at the

environmental level and OHS

To carry out the external management of the residues

To take care of the minor injuries

To support technically the Processes of Manufacture

To carry out periodic tests to the procedures of preparation and response before

emergencies

To prepare and to execute Programs of calibration / verification (including software

when necessary)

To update and to communicate the Legal Requisites applicable to the activities,

products and services carried out and given by the Organization

To evaluate periodically the fulfillment of the Legal Requisites and others applicable,

and to keep records of this evaluation

To manage the Legal Fulfillment with the interested Parties

To keep the program: School of the Quality

To coordinate the activities of Continuous Improvement and QIT

Mgt. System Processes

Requisites of Mgt. System

Contract with Certifier entity

Reports of previous Audits

Indicators of management Audits

To plan and to carry out the Audits of the Mgt. System

NEZCP026

NTC ISO 9001:2000

NTC ISO 14001:2004

NTC OHSAS 18001:2000

QIT

Manager of PTQ

Internal auditors

Audited Persons

Plans of Actions of Improvement

Records

Managerial report of Audits

Certificates of Mgt. System

General manager

Certifier Entity

Processes of Mgt. System

Interested Parties

QIT

Coordinators of Evacuation

NEZCP046

Manager of PTQ

Assistants of PTQ

Competent and Careful Personnel

Minutes of the QIT

Plans of Action

Records of Continuous Improvement

Quality School

BA PTPR 1LAA000022

Updated Matrix of Legal Requisites

Supports of Legal Fulfillment

Records

PT Division

Interested partiesCertifier Entity

Customers

CIDET

PT Division

PT Division

Interested parties

Auditors

Certifier Entity

Manager of PTQ

Manager of PTH

Records of Operational Control

Quality records

Record of Evaluation of SimulationsEquipments and devices of measurement and

monitoring calibrated / verified

Records

Equipped Classrooms

Internal auditors

ProcessofImprovement

ofthe

IntegralQuality

Computing EquipmentsQIT/Managing Boards

PTQ Manager (Representative of the Direction for Mgt. System) Equipped offices

HUMAN RESOURCES


Brigade of Security

Room of Metrology

MANAGEMENT OF RESOURCES

To 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.


Interested parties

PT Division

Interested parties

PlanningoftheMgt.System

Activities of the Processes

Operational Controls

Practices of response before

Emergencies

Residues of the ProcessesInformation of Security of Chemical

Products

Equipments of following up and

measurement (It includes software

when necessary)

Mgt. System ProcessesCustomers

OperationalcontrolandResponsebeforeEmergencies

Legalconformity

Integral Quality Management

Integral Quality Manager

Scope of the Mgt. System

Process map

Program of Management

Graphic of Central Control

Matrix of Environmental Aspects

Matrix of Dangers and Risks

Matrix of Legal Requisites

Matrix of Administration of Changes

COABB

PT Division

Interested parties

MGIPTG001

NTC ISO 9001:2000

NTC ISO 14001:2004

NTC OHSAS 18001:2000

NEZCP061

NEZCP045

NEZCP046

NEZCP060

Manager of PTQ

QIT

ITPTQ001 - 002

PAPTQ006 - 007 - 008 - 009 - 010

PAPTH002 - 003

PAZCC022

PAZCH015 - 016

NEZCP063 - 064 - 065

ITPTQ040 - 041 - 042

PAPTQ003PAPTQ004

PAPTQ005

PAPTQ013

PAPTQ027

PAPTQ028

ITPTQ006 - 008

ITPTQ010

ITPTQ015

ITPTQ035

ITPTQ037 - 039

Manager of PTQ

Assistants of PTQ

Process managers

Technician Laboratory of Oils

OperatorsSuppliers

Contractors

Visitants

Engineer Room of Tests

Users of equipments /

devices

Users of Mgt. System

Agenda QIT

Activities of the Organization

Changes to the New Processes

or Modifications of the Requisites

Results of verifications of Operational

Control

Previous evaluations

Communications of Interested Parties

Information Technology Resources (Intranet, internet, databases: SSA, CCRP, Borwin, CRS)

RESOURCES OF INFRASTRUCTURE

Assistants of Integral Quality

OHS committee Brigade Location

Nursing station

Room of conferences with audio-visual aids (video beam, VHS, TV and projector)

Matrix SGI

Wasted Chemical Prod.

Management ToolsCritical Com. Legal Reg. Measurement and MonitoringEnviromental Aspects Dangers and Risks Management Prog.


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PROCESS

LEADER

OBJECTIVE

SUPPLIER INPUTSUBP

ACTIVITY DOCUMENTS RESPONSIBLE OUTPUT CLIENT

To prepare a program of Engineering

To study Technical Specifications

To review or to perform Check List

To do Order Clearing

To prepare a Pre-design

To do a Technical Offer

To draw up electrical design

To do a Structure in BaaN

To carry out Cards of Manufacture

To prepare information for tests

To carry out a design of Active Part

To carry out a design of assemble,

connections y cubing.

To carry out a design of isolations (only

TrafoStar)

To carry out Plans for approval (if it is

needed by the client)

To carry out external design

To do a Structure in BaaN

To review, to verify and to validate the

Electrical and/or Mechanical Design

To control changes of Electrical and/or

Mechanical design

Electrical Design Engineer

Requests of Changes of Design

MANAGEMENT OF RESOURCES

Mechanical Design Engineer

Computing Equipment (computers, printer and plotter)

Information technology resources (Intranet, Internet, software of design, database BA)

PTO

ITPTE001

PAPTE001

PAPTE003

PTE

PTM

PTS

BA

PTM

PTE

BA PTPR

Technical specifications of the Client

Technical and Commercial offer

Technical norms

Technical instructions of BA

ITPTE002 - ITPTE009

D

esignforOffers

ITPTE001

ITPTE010

ITPTE011


Technical and Commercial offer

Technical norms


Electrical Design

Technical norms


Price Database


Manager of Engineering Equipped offices

HUMANS INFRASTRUCTURE

PTM

PTE

BA PTPR

Electrical Design

Electrical Designers

Electricaldesignfor

production

PTO,

PTQ

PTD

PTP

Electrical and Mechanical

Designers

Engineering

Manager of Engineering

To 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 of

engineering and materials foreseen in the selling are met, and also the technical requisites of the product are met.

Program of Engineering

Records of Order Clearing PTO



DesignersPlanningRecord Meeting SUM

Plan of Invoicing

Technical specifications

Mechanicaldesignfor

production

Plans of Manufacture

Technical Support

PTD

PTP

PTO

ReviewandControl

ofChanges

PAPTE004

PAPTE002



Designers

ITPTE002 - ITPTE009

Designers of Offers

New Designs

Cards of Manufacture

Plans

Electrical design

Structure of Materials

Data for Tests

Technical Support

PTD

PTP

PTO

Mechanical Design

Room for Tests

Technical Offer PTM

PTP

PTD

Mechanical Designers

Matrix SGI

Remainders Chemical Prod. Management ToolsCritical Com. Legal Reg. Measurement and Monitoring

Enviromental Asp. Dangers and Risks Management Prog.


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PROCESS

LEADER

OBJECTIVE

SUPPLIER INPUTSUBP

PARTICULAR ACTIVITIES DOCUMENTS RESPONSIBLE OUTPUT CUSTOMER

PTP

BA PTPR

PTQ

PTE

PTO

Product in Process

Criteria of Acceptance

Sigma Cards

Cards of Program of Manufacture

Plans / designs

General Schedule Macro planningProcesscontrol

To inspect and to test the product in

process

PAPTP001,

PAPTQ001,

ITPTP016,

Supervisor Control of

Processes of PTPQuality records (Sigma Cards)

Sub process of Room of

Tests

To prepare isolations

To paper conductors

To wind

To dry and to press Windings

To dry and to press Windings

To separate plates by groups

To prepare table for stacking

To stack, press and put vertically the cores

To strain or to apply Asecond

To mount Windings in core

To close top yoke

To connect Active Part

To prepare cubing

To dry Active Part

To tight again and to cube

To mount accessories

To prove preliminarily the Airtightness

To try and to analyze the Dielectric Oil

To do vacuum and to fill with oil

To rest and To impregnate

To place control wiring

To Carry out electrical Tests

To test control wiring

To prepare protocols of tests

Warehouse

Standard and customized

materials, approved, and minor raw

materials

Windingm

anufacture

ITPTP004,

ITPTP005,

ITPTP006,

ITPTP024,

ITPTP025,

ITPTP026,ITPTP036,

ITPTP039,

ITPTP043,

ITPTP046

Power Transformers

Production Manager

To 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 Organization

Leader and Operators of

WindingsBlock of Windings

Sub process of

Assembling and

Connections

PTS

Sub processes of Cores,

Windings and Warehouse

Windings

Core

Clamps

SwitchPlans/Designs

ActivePa

rtAssembly

ITPTP026

ITPTP009

ITPTP044


Assembling

Active part assembled and connected Sub process of cubing

CoreManufacture

ITPTP003

ITPTP008


AssemblingVerticalized Core

Sub process of

Assembling and

Connections

Sub processes of Assemble and

Connections and Warehouse

Active connected part

Tank

Accessories

Processed and proved oil

Plans/Designs

TankingandFinalAssembly

ITPTP015,

ITPTQ029,

ITPTP037,

ITPTP038,

ITPTP040,

ITPTP042


Assembling

Transformer finished and ready for

tests

Sub process of Room of

Tests

PTP

PTE

Transformer for testsGeneral information of Tests

FinalTes

tPAPTQ002,

ITPTQ011,ITPTQ012,

ITPTQ014,

ITPTQ016 - ITPTQ022

ITPTQ032

Engineer of Room of TestsTransformer released by Room of

Tests, Protocols of Tests, Minutes of

Controlling, Reports of Feedback to

the Design

PTP, PTO,

PTE

Matrix SGI

Waste Chemical Prod. Managment ToolsCritical Com.

Legal Reg. Mesasurement and MonitoringEnviromental Asp. Dangers and Risks Managment Prog.


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Intern

QHS

QIT

Managers Team

Quality

Carlos Ossa

H & S

M. Marn L. Montoya Samuel Zulug

Environmental

Paula Mesa

Safety Brigade

Evacuation

Coordinators

Integral Quality Organization Chart

General Management

BASC

Quality School

Instructors

QHSE Management


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A little of history (Integral Quality milestones)

1990: ABB Group arrives to Pereiras factory through a global acquisition of

Westinghouse T&D segment 1996: Quality Management System is certified with ISO 9001 by BVQi

1999: Environmental Management System is certified with ISO 14001 by BVQi

2002: Philip Crosbys Quality Improvement Process is implemented

QIT: Quality Improvement Team is established with the local TopManagement

QS: Quality School program is launched to give all people trainin in

Quality issues, technical competence and to encourage their Quality

Awareness

2003: Six Sigma tool is implemented for TrafoStar power transformers

2005: Occupational Health and Safety Management System is certified with

OHSAS 18001 and the 3 Management Systems are integrated in QHSE

2006: BASC Managemen System is certified by the WBO (Business Alliance

for Secure Commerce)


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Last 10 years improvement profile and our VISION

2002

QIP

1

2005

ISO9

001

ISO1

4001

1996 1999

OHSAS18001

+SGIQHSE

2009

2

3

4

5

6

2006

BASC

World Class Manufacturer


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We have a great VISION

In 2009 ABB Pereira will be a World ClassManufacturing plant

Happy people doing well their work

General view of windings shop in Chonqing All employees celebration


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Zero Failures

Zero ImpactsZero Accidents

TPT & TTPTreduction

On Time Delivery Customer Satisfied

More orders

Best pricesGreater EBITStability & Safelabol

COPQs reduction

Cash Flow

A good present for

Everybody!

The Integral Quality way


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Our Integral Policy show us the way


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QHSE and BASC Policy (Translation)

Do well our work since first time to get Customer's

Satisfaction by means of Quality Products and QualityServices delivered on time, producing the budgetedprofitability.

To get this, our commitment is:

Promote people's Competence and Awareness as our greatest asset To rise the life's quality of our employees by means of the continuous

improvement in H&S issues

Reduce waste generation and natural resources consumption in ourprocesses

Improve continuously our Processes efficacy

Prevent illegal practices in our processes (terrorism, illegal trade,drugs traffic, etc.)

Fulfill all the legal requirements in our processes


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Our Zero Defects Objectives

ZD does not mean that we will not have failures, it means

that we will not be happy with any failure!

Quality ISO 9001

100% OTD

Zero Test

Failures

100% Customer

Satisfaction

HUACALTANQUE

CO NS E RV ADO R

PROTECCION

AISLADORES

HUACAL

RADI ADO RE S

OHSAS 18001

Zero Lost Day

Incidents

Environ. ISO 14001

Zero Oil Spilling

QHSE Objectives

Zero COPQ

Zero Electrical

Energy Waste

BASC

Zerocontamination

Quality ISO 9001

100% OTD

Zero Test

Failures

100% Customer

Satisfaction

HUACALTANQUE

CO NS E RV ADO R

PROTECCION

AISLADORES

HUACAL

RADI ADO RE S

Quality ISO 9001

100% OTD

Zero Test

Failures

100% Customer

Satisfaction

HUACALTANQUE

CO NS E RV ADO R

PROTECCION

AISLADORES

HUACAL

RADI ADO RE SHUACALTANQUE

CO NS E RV ADO R

PROTECCION

AISLADORES

HUACAL

RADI ADO RE S

OHSAS 18001

Zero Lost Day

Incidents

Environ. ISO 14001

Zero Oil Spilling

QHSE Objectives

Zero COPQ

Zero Electrical

Energy Waste

BASC

Zerocontamination


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The Quality Strategy

1. Philip Crosbys QIT QualityImprovement Process:

n Quality School

n Quality Improment Team

n Zero defects philosophy

2. Integration QHSE + BASC

Philip Crosby

ce


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Quality Improvement Process launchingsinc

e

2002

ce


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Quality Schools principle:The Competence and Consciousness of our employees

are our greatest assets. BA PPTR Mnger.

since

2002 Quality Improvement Process launching

ince


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since

2002 Quality School launching

Quality Class Room

ince


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QS: Every body talking same languaje:QS: Every body talking same languaje: Quality!Quality!

u Quality Throughout Work Team (QTWT)

Each Improvement P ro jec t

1000 USD Sav ings

Course for Blue collarsCourse for Blue collars(15 Hours in 6 weeks)(15 Hours in 6 weeks)

Each Improvement P rojec t

1000 USD Sav ingsuu Quality EducationQuality Education

System (QES)System (QES)

Course for White collarsCourse for White collars(25 Hours in 10 weeks)(25 Hours in 10 weeks)

Course for ManagersCourse for Managers QITQIT

(12 Hours in one weekend)(12 Hours in one weekend)

Course to get internal Quality InstructorsCourse to get internal Quality Instructors

since

2002 Quality School strucutre

ince


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EMC:

General Manager

Quality Manager

Controller

Logistic Manager

Human Resource Manager

Engineering Manager

Production Manager

Marketing Manager

Supply Manager

Order Handling Manager

Quality Improvement Teamsinc

e

2002

The QIT in 2002. Today it has 10 membersand they meet each two weeks with the

following agenda


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Basic Cyclic Agenda

Quality Improvement Team

NCR DistributionTransformers

Audit ReportsSix Sigma &

dpmos

5S and

Housekeeping

NCR PowerTransformers

EnvironmentalManagment

System

Follow up toQHSE Objectives

Metalshopsupplies

Follow up

OHSAS 18001

Training Program& Quality School

Quality ActionPlans on going

ManagmentSystems

Integration

CCRP

and

Customer

Satisfaction

Balance ScoreCard

QualityPerformance

Index

ImprovementProjects

- QS -

4th Meeting3th Meeting2nd Meeting1st Meeting

In each session at least three of this topics are reviewed


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1. People develope a holisitic processes approach

2. One integral Policy easier to implement and follow

3. Less number of internal and external audits, we pass from 12 to 4 per year

4. One integral Manager s review5. Integral operational control for Environmental and OHS systems

6. One integral induction program for new employees

7. More efficient use of IS resources and leaner documentation

8. Less number of registers

9. Prevention of lawful nonconformity

10. One integral Manual book (it is an interactive document)

Advantages we have from the QHSE integration

QHSE + BASC Integration


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QHSE + BASC Certifications

ISO 9001

since 1996

ISO 14001

since 1999

OHSAS 18001

since 2005

BASC

since 2006


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BELIEFS

SYSTEM ISO 9001, ISO 14001,OHSAS 18001, BASC, etc

PROCEDURES MP, TI, Manuals, etc.

BEHAVIORS

VALUES

Traditional

Focus

World Class

Focus

Certifies are not enough to be World Class

STRUCTURE Resources


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By Abraham Maslow (1908 1970)

QHSE Management evolution


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The Integral

Employee

knows, wantsand has will

power!


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June /08Test Rooms accreditation acc. to ISO IEC 17025

December /09Iberoamerican Quality Management Award

December /08Columbian Quality Management Award

December /08Integrate QHSE + BASC + SR

December /08Implement Social Responsibility Management System

acc. to SA 8000 Standard

DATEDESCRIPTION

Next steps


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abb power transformers

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