INTERNSHIP REPORT: EVALUATION OF FEDCOR’S DISTRIBUTION TRANSFORMER MANUFACTURING PROCESS

By: Felimar T. Resplandor

INTRODUCTIONThe internship program is one of the

requirements in the Masters in Management Degree Program of Graduate School and Professional Studies (GSPS) of the Colegio de San Juan de Letran Calamba (CSJLC). This is to forge strong academe-industry linkage to match industry demand and for the student volunteer consultant to have a hands on experience as consultant.

Conceptual Framework(1) Documentation (Macro Level)

Mission and Vision

QESH Policy

Core Values

(Documentation) (Micro Level)

Procedures

Work Instruction

Equipment/machines and Materials

Manpower and Methods

(2) Observation and Analysis:

Observe actual management practices.

Comparing operation with the set procedures and work instruction

Observe and analyze the four M of Operation

(3) Recommends:

Recommends enhancement to increase plant efficiency and capability.

FEDCORThe company is the First Electro Dynamics

Corporation (Fedcor), incorporated in 1991 as a wholly owned subsidiary of First Philippine Holdings Corp. (FPHC) to commercialize the manufacture of electrical products being developed by FPHC-CARD. It is located in the First Philippine Industrial Park, Sto. Tomas, Batangas.

Products and ServicesFedcor manufactures:

600V current transformer pole type distribution

transformers. Services repair of pad mounted

transformerspole type transformersautomatic voltage

regulatorsload break switchesReclosersectionalizers and oil

switches.

FEDCORFedcor is an Integrated Management System certified company.  It is also familiarizing itself with Six Sigma practices to result in cost savings for the company. Fedcor was recently award Investors in People status.  Its facilities are located in First Philippine Industrial Park, Sto. Tomas, Batangas.

MISSION“Our business at FIRST ELECTRO DYNAMICS CORPORATION is to create value by supplying high quality products and services in the distribution, control, and efficient utilization of electric energy for the domestic market”VISION“To be the products provider and service of choice in the electric industry”

FEDCOR QESH Policy

Continually satisfy our customer by delivering quality products and services;

Protect and preserve the environment by preventing the release of pollutants, reducing waste, optimal use of raw materials, conserving energy, water, fuel, and other sources;

Protect our employees and stakeholders by keeping and maintaining safe and healthy working environment;

FEDCOR QESH Policy

Comply at all times with relevant legislations, regulations, and other requirements to which Fedcor subscribes.

We shall continually improve our integrated management system through a periodic review for adequacy and suitability.

We shall keep and maintain the company financially healthy and do this in partnership with our Stakeholders”

FEDCOR Core Values

Customer FocusFamily Spirit and TeamworkIntegrityPassion for ExcellenceCare and Respect to our Stakeholders

FEDCOR Organization

President and COO

General Manager

Engineering and Shop Floor

Management Head

TS/Sales and Marketing Head

Supply Chain Management

&Business Excellence Head

Human Resource Administration and Business

Excellence Head

Finance and Accounting Head

Engineering Shop Floor

General Manager

Engineering and Shop Floor Management

Head

Production Engineer Product Engineering Engineers

Plant Engineering Head

Quality Assurance Engineer

PLE Process Lead man

PLE Staffs

Quality Assurance Process Lead man

QA Technicians

Process Lead man/ Assistant Process and Production Personnel

WindingReceive information and review

pertinent documents

Prepare units to be processed

Winding of Secondary Wire

Winding of Primary Wire

Endorse wound coil for compression (Internal Assembly)

File and Maintain Records

Internal Assembly

Receive wind coil from winding section

Prepare units to be processed

Compression of wound coil

Baking of compressed coil

Unloading and dismantling of compressed coil

Lacing of compressed coil

Tap Changer Assembly

Core coil Testing

Yes

In-Process testing

A

PassQA EvaluationNo

Pass

Endorse unit to final assembly

File and Maintain records

QA Evaluation

Yes

No

External Assembly

Receive and review pertinent documents

Received core coil and transformer components

Drying of busing and core coil

Tanking of core coil

Vacuuming and initial oil filling

Attachment of labels

A

Mounting of bushing and connecting of terminal

leads

Final oil filling

Endorsement of unit for final testing

Final Testing

Final Completion

Endorsement of unit to warehouse

A

Strength Weakness

ISO certified and programs are

clearly stated toward business

excellence.

Procedure manual and work

instruction are intact and

stipulated clearly.

Procedures manual and work

instruction are available in the

production area for reference of

the production personnel

Use of Job ticket and wiring tag

are properly observed for

monitoring, traceability, and

accountability.

Supply of materials is beyond the

control of Fedcor (control by

Philec-Fedcor sister company and

customer) which sometime cause

delay of material supply.

Number of man power is limited in

the event there is an increase of

production (especially in the

material preparation area and

testing)

Some winding machines are using

analog counter which affects the

accuracy of winding count.

The monitoring of winding tension

is being done manually by the

operator which cause inaccurate

winding tension in the coil

Strength Weakness

Safety in the production area is

observed by using PPE, work

instruction, warning devices, and

signs.

Personnel are well trained in their

area of responsibility.

Equipment to test the parameters

of DT as set in the design

specifications is available and

calibrated yearly.

Fedcor can accommodate both

production and repair of DT

Finish core coil are expose to

unintended moisture and dust.

Compression of coil is monitor

manually which affects the

efficiency of the coil compression.

Oven monitoring device is limited,

there is no visible indicator in

front or oven door which will

indicate that it is in operation.

Some equipment is outdated like

winding machine, lacing table, and

oven.

Opportunities Threat

Electricity in the Philippines is

developing continuously, meaning

the market in electrical industry is

growing.

There are only few in the industry

who manufacture DT in the

Philippines.

Imported transformer is now being

used by some utility companies and

MERALCO.

There are industries who are already

offering transformer repairs like

Fedcor.

Winding Cause-and-Effect Analysis

Winding Failed to QA test

Tension monitoring

Winding area environment

Number of Manpower

Count Monitoring

Training and/or Ability

Manpower

Method/Environment

Type

Maintenance

Materials (Copper and Aluminum)

Age

Winding Machine

Suppliers

Quality Test Delivery time

Result of Cause-Effect Analysis(Winding)Material (Probably factor to failure)

Supplier is beyond control of FedcorQuality tests of supplied is done randomly

MachineOld machines, age more than 15 to 20 yearsMachine counter is analog

Manpower (factor to failure)Manpower is limited, one winder have to work semi-

manual, continuously the whole dayMethod (factor to failure)

Winding tension monitoring is done manuallyWinding section is exposed to unwanted dust and moisture

Internal Assembly Cause-and-Effect Analysis

Vaccum

Internal Assembly Failure

Materials

Age

Machines/ equipment

Suppliers

Quality Test Delivery time

Oven - Monitor

Coil CompressionLacing

Number of Manpower

Training and/or Ability

Manpower

Method/ Environment

Temperature MonitorCoil Tapping

Result of Cause-Effect Analysis(Internal Assembly)Material (Probably factor to failure)

Supplier is beyond control of FedcorQuality tests of supplied is done randomly

Machine (Lacing Table and Oven)Old lacing table, Non-hydraulicOven – Temperature monitoring is limited (Realtime temp.

monitoring)Oven operation indicator is limited (for operator safety)

Manpower (factor to failure)Manpower is limited

Method (factor to failure)Compression is done manually Lacing bolt tightening is also done manually

Final Assembly Cause-and-Effect Analysis

Final Assembly Failure

Bushing DryingVacuuming

Number of Manpower

Training and/or Ability

Manpower

Method/ Environment

Oil FillingBushing Mounting

Vacuum

Materials

Age

Machines/ equipment

Suppliers

Quality Test Delivery time

Oven - Monitor

Oil Filler

Result of Cause-Effect Analysis (Final Assembly)Material (Probably factor to failure)

Supplier is beyond control of Fedcor Quality tests of supplied is done randomly

Machine (Vacuum, Oven, and Oil Filler) Oven – Temperature monitoring is limited (Realtime temp.

monitoring) Oven operation indicator is limited (for operator safety) Non so much in vacuum and oil filling equipment (both are

efficient)Manpower (factor to failure)

Manpower is limitedMethod (factor to failure)

After oil filling, tank is being open and oil is exposed to contamination

Bushing drying sometime fails

Summary of Findings

Fedcor is an ISO 9001, ISO 14001, and OHSAS 18001 certified and it is continuously observed in its entire endeavor.

Quality manual (QEHSM) such as procedure and work instruction are intact and updated and available in the production area for personnel reference.

Health and safety is observed at all times, emergency responses are clearly stipulated in bulletin boards for reference.

While all winding machine are working and properly maintain, the winding counter is still analog and its winding tension is done manually.

Summary of Findings

Winding compression and its measurement is being done manually.

Oven operation and temperature monitoring is very limited, since oven operation status in not visible in the front panel and temperature is monitored manually.

Some core coil assemblies are exposed to unwanted dust and moisture from the oven and surroundings.

Material preparations and QA personnel is limited to accommodate increase of production volume.

Conclusion and Implications

The certification of Fedcor in ISO 9001, ISO 14001, and OHSAS 18000 is an advantage towards continuous business excellence;

Availability of Quality Manual (QEHSM) will ensure that all procedures are within standard and will produce quality products;

Outdated machines / equipment affects overall plant efficiency and capability to compete with other company of the same nature;

Limited personnel in some area of the production cause delay in the production time.

Recommendations

Fedcor should establish a detailed equipment and facility development program to address issues on equipment upgrading in order to increase plant efficiency and capability.

Enhance employee retention program to lessen employee’s turnover rate.

Thank You