abb power transformers
TRANSCRIPT
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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
Mgt. System Processes
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.
Mgt. System Processes
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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Code: F01- MGIPTG001
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 specifications of the Client
Technical and Commercial offer
Technical norms
Technical instructions of BA
Electrical Design
Technical norms
Technical specifications of the Client
Price Database
Technical instructions of BA
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
Manager of Engineering
Electrical and Mechanical
DesignersPlanningRecord Meeting SUM
Plan of Invoicing
Technical specifications
Mechanicaldesignfor
production
Plans of Manufacture
Technical Support
PTD
PTP
PTO
ReviewandControl
ofChanges
PAPTE004
PAPTE002
Manager of Engineering
Electrical and Mechanical
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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Code: F01- MGIPTG001
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
Leader and Operators of
Assembling
Active part assembled and connected Sub process of cubing
CoreManufacture
ITPTP003
ITPTP008
Leader and Operators of
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
Leader and Operators of
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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