Post on 19-Feb-2015
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
MARKETING &
SALES
ENGINEERING
DISTRIBUTION TRANSFORMERS
POWER TRANSFORMERS
LOGISTIC
SUPPORT PROCESSES*
SUPPLYMNGMNT.
HUMANMNGMNT.
INFORMATION SYSTEMS
INTEGRAL QUALITYMNGMNT.
FINANCIAL CONTROL
MAINTENANCE & GENERAL SERVICES
SUPP
LIER
S
CUSTOMERS
SERVICE
* Mutual Interaction
CO
MM
UN
ITYSTRATEGIC MANAGEMENT
TRANSFORMER TESTS & OIL ANALYSIS
Code: F01- MGIPTG001
PROCESS
LEADER
OBJECTIVE
SUPPLIER INPUT
SU
B
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. SystemContract with Certifier entityReports of previous Audits Indicators of management A
udits
To plan and to carry out the Audits of the Mgt. System
NEZCP026NTC ISO 9001:2000
NTC ISO 14001:2004NTC OHSAS 18001:2000
QITManager of PTQInternal auditorsAudited Persons
Plans of Actions of ImprovementRecords
Managerial report of AuditsCertificates of Mgt. System
General managerCertifier Entity
Processes of Mgt. SystemInterested Parties
QIT
Coordinators of Evacuation
NEZCP046Manager of PTQ
Assistants of PTQ
Competent and Careful PersonnelMinutes of the QIT
Plans of ActionRecords of Continuous Improvement
Quality SchoolBA PTPR 1LAA000022
Updated Matrix of Legal Requisites Supports of Legal Fulfillment
Records
PT Division Interested parties
Certifier EntityCustomers
CIDET
PT Division
PT DivisionInterested parties
AuditorsCertifier Entity
Manager of PTQManager of PTH
Records of Operational ControlQuality records
Record of Evaluation of SimulationsEquipments and devices of measurement and
monitoring calibrated / verifiedRecords
Equipped Classrooms
Internal auditors
Pro
cess
of I
mpr
ovem
ent
of th
e In
tegr
al Q
ualit
y
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 ProcessesInterested parties
PT DivisionInterested parties
Pla
nnin
g of
the
Mgt
. Sys
tem
Activities of the Processes
Operational ControlsPractices of response before
EmergenciesResidues of the Processes
Information of Security of Chemical Products
Equipments of following up and measurement (It includes software
when necessary)
Mgt. System ProcessesCustomers
Ope
ratio
nal c
ontro
l and
Res
pons
e be
fore
Em
erge
ncie
s Le
gal c
onfo
rmity
Integral Quality Management
Integral Quality Manager
Scope of the Mgt. SystemProcess map
Program of ManagementGraphic of Central Control
Matrix of Environmental AspectsMatrix of Dangers and Risks
Matrix of Legal RequisitesMatrix of Administration of Changes
COABBPT Division
Interested parties
MGIPTG001NTC ISO 9001:2000
NTC ISO 14001:2004NTC OHSAS 18001:2000
NEZCP061NEZCP045NEZCP046NEZCP060
Manager of PTQQIT
ITPTQ001 - 002PAPTQ006 - 007 - 008 - 009 - 010
PAPTH002 - 003PAZCC022
PAZCH015 - 016NEZCP063 - 064 - 065ITPTQ040 - 041 - 042
PAPTQ003PAPTQ004PAPTQ005PAPTQ013PAPTQ027PAPTQ028
ITPTQ006 - 008ITPTQ010ITPTQ015ITPTQ035
ITPTQ037 - 039
Manager of PTQAssistants of PTQProcess managers
Technician Laboratory of OilsOperatorsSuppliers
ContractorsVisitants
Engineer Room of TestsUsers of equipments /
devices
Users of Mgt. SystemAgenda QIT
Activities of the OrganizationChanges to the New Processes
or Modifications of the Requisites
Results of verifications of Operational Control
Previous evaluationsCommunications of Interested Parties
Information Technology Resources (Intranet, internet, databases: SSA, CCRP, Borwin, CRS)
RESOURCES OF INFRASTRUCTURE
Assistants of Integral Quality
OHS committee Brigade LocationNursing station
Room of conferences with audio-visual aids (video beam, VHS, TV and projector)
Matrix SGI
Wasted Chemical Prod.Chemical Prod.
Management ToolsCritical Com. Legal Reg. Measurement and MonitoringEnviromental Aspects Dangers and Risks Management Prog.
Code: F01- MGIPTG001
PROCESS
LEADER
OBJECTIVE
SUPPLIER INPUT
SU
BP
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 PartTo 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 EngineerComputing Equipment (computers, printer and plotter)Information technology resources (Intranet, Internet, software of design, database BA)
PTOITPTE001PAPTE001PAPTE003
PTEPTMPTSBA
PTMPTE
BA PTPR
Technical specifications of the ClientTechnical and Commercial offer
Technical normsTechnical instructions of BA
ITPTE002 - ITPTE009
Des
ign
for
Offe
rs
ITPTE001ITPTE010ITPTE011
Technical specifications of the ClientTechnical and Commercial offer
Technical normsTechnical instructions of BA
Electrical Design
Technical normsTechnical specifications of the Client
Price Database Technical instructions of BA
Manager of Engineering Equipped offices
HUMANS INFRASTRUCTURE
PTMPTE
BA PTPRElectrical Design
Electrical Designers
Ele
ctric
al d
esig
n fo
r pr
oduc
tion
PTO, PTQPTDPTP
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 EngineeringRecords of Order Clearing PTO
Manager of Engineering Electrical and Mechanical
Designers
Pla
nnin
gRecord Meeting SUMPlan of Invoicing
Technical specifications
Mec
hani
cal d
esig
n fo
r pr
oduc
tion
Plans of Manufacture Technical Support
PTDPTPPTO
Rev
iew
and
Con
trol
of C
hang
es
PAPTE004PAPTE002
Manager of Engineering Electrical and Mechanical
Designers
ITPTE002 - ITPTE009
Designers of Offers
New Designs
Cards of ManufacturePlans
Electrical designStructure of Materials
Data for TestsTechnical Support
PTDPTPPTO
Mechanical DesignRoom for Tests
Technical Offer PTM
PTPPTD
Mechanical Designers
Matrix SGI
RemaindersRemainders
Chemical Prod. Management ToolsCritical Com. Legal Reg. Measurement and MonitoringMeasurement and Monitoring
Enviromental Asp. Dangers and Risks Management Prog.
Code: F01- MGIPTG001
PROCESS
LEADER
OBJECTIVE
SUPPLIER INPUT
SU
BP
PARTICULAR ACTIVITIES DOCUMENTS RESPONSIBLE OUTPUT CUSTOMER
PTPBA PTPR
PTQPTEPTO
Product in ProcessCriteria of Acceptance
Sigma CardsCards of Program of Manufacture
Plans / designsGeneral Schedule Macro planning
Pro
cess
con
trol
To inspect and to test the product in process
PAPTP001, PAPTQ001, ITPTP016,
Supervisor Control of Processes of PTP
Quality 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
To test airtightness, to dismantle external accessories, to do identification and
marking, to coordinate their packaging
To register consumptions in BaaN and to do entry to Warehouse
Technician of Laboratory of Oils
Operator of Cores and Active Part
Chief of Room of Tests
Operator Laboratory PTP
Wiring Operator
Operator of Connections
Operator of Shipments
Operator of Cubing and Final Assembly
Assistant of Assembling
Assistant of Materials
Assembling Leader
Operator of Oils
Planner of Production
Supervisor of Production
INFRASTRUCTURE
Manager of Production Plant of manufacture of Power transformers
Equipped offices
Sub process of Room of TestsPTSPTE
Transformer ready for shippingRegistration in BaaN PTO
Rea
dyin
g an
d O
pera
tive
Shi
ppin
g
ITPTP038ITPTP045
Leader and Operators of Assembling and Shipping
Released Transformer for ShipmentPackaging
Packing List
WarehouseStandard and customized
materials, approved, and minor raw materials
Win
ding
man
ufac
ture
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 Windings
Block of WindingsSub process of Assembling and
Connections
PTSSub processes of Cores,
Windings and Warehouse
WindingsCore
ClampsSwitch
Plans/Designs
Act
ive
Par
t Ass
embl
y
ITPTP026ITPTP009ITPTP044
Leader and Operators of Assembling
Active part assembled and connected Sub process of cubing
Cor
e M
anuf
actu
re
ITPTP003 ITPTP008
Leader and Operators of Assembling
Verticalized CoreSub process of Assembling and
Connections
Sub processes of Assemble and Connections and Warehouse
Active connected partTank
AccessoriesProcessed and proved oil
Plans/Designs
Tan
king
and
Fin
al A
ssem
bly
ITPTP015, ITPTQ029, ITPTP037, ITPTP038, ITPTP040, ITPTP042
Leader and Operators of Assembling
Transformer finished and ready for tests
Sub process of Room of Tests
PTPPTE
Transformer for testsGeneral information of Tests
Fin
al T
est
PAPTQ002, ITPTQ011,ITPTQ012,ITPTQ014,
ITPTQ016 - ITPTQ022ITPTQ032
Engineer of Room of Tests
Transformer released by Room of Tests, Protocols of Tests, Minutes of Controlling, Reports of Feedback to
the Design
PTP, PTO, PTE
Financial resourcesOperator Assembly Windings
Paper Operator
Teams of safety and personal protection
Equipment for the handling of heavy loads
Operator Windings
Assistant Assembly Windings
MANAGEMENT OF RESOURCES
Leader of WindingsEquipment of inspection, such as micrometers, gauges and others, related to the technical instructions
Machinery and equipment of plant to manufacture the product in accordance with the provisions of the instructions of BA and the Production Manuals of LDT and TrafoStar
Operator of Insulations
Assistant of Windings
Computing equipment
Information 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 Oils
HUMANS
Matrix SGI
Waste Chemical Prod. Managment Tools Critical Com.Critical Com.
Legal Reg. Mesasurement and MonitoringEnviromental Asp. Dangers and Risks Managment Prog.
ABB
Internal AuditorsQHSE - BASC
QITManagers´ Team
Quality
Carlos Ossa
H & SM. Marín – L. Montoya Samuel Zuluága
Test Processes
JCV – JM - HV
EnvironmentalPaula Mesa
SPT TR
DTR TR
Oil Analysis
Safety Brigade
Evacuation Coordinators
OHS Advisor
Integral Quality Organization Chart
General Management
BASC
Quality School Instructors
QHSE Management
A little of history (Integral Quality milestones)
Ø 1990: ABB Group arrives to Pereira´s factory through a global acquisition ofWestinghouse T&D segment
Ø 1996: Quality Management System is certified with ISO 9001 by BVQi
Ø 1999: Environmental Management System is certified with ISO 14001 by BVQi
Ø 2002: Philip Crosby´s Quality Improvement Process is implemented
Ø QIT: Quality Improvement Team is established with the local TopManagement
Ø QS: Quality School program is launched to give all people trainin in Quality issues, technical competence and to encourage their Quality Awareness
Ø 2003: Six Sigma tool is implemented for TrafoStar power transformers
Ø 2005: Occupational Health and Safety Management System is certified withOHSAS 18001 and the 3 Management Systems are integrated in QHSE
Ø 2006: BASC Managemen System is certified by the WBO (Business Alliancefor Secure Commerce)
Last 10 years improvement profile and our VISION
2002
QIP
1
2005
ISO
900
1
ISO
140
01
1996 1999O
HS
AS
180
01
+ S
GI Q
HS
E
2009
2
3
4
5
6 σσ
ττ2006
BA
SC
World Class Manufacturer
We have a great VISION
Ø In 2009 ABB Pereira will be a World ClassManufacturing plant
Ø Happy people doing well their work
General view of windings shop in Chonqing All employees celebration
Zero FailuresZero ImpactsZero Accidents
TPT & TTPT reduction
On Time Delivery Customer Satisfied
More orders
Best pricesGreater EBITStability & Safe labol
COPQ’s reduction
Cash Flow
A good present for Everybody!
The Integral Quality way
Our Integral Policy show us the way
QHSE and BASC Policy (Translation)
Do well our work since first time to get Customer's Satisfaction by means of Quality Products and Quality Services delivered on time, producing the budgeted profitability.
To get this, our commitment is:
Ø Promote people's Competence and Awareness as our greatest asset
Ø To rise the life's quality of our employees by means of the continuous improvement in H&S issues
Ø Reduce waste generation and natural resources consumption in ourprocesses
Ø Improve continuously our Processes efficacy
Ø Prevent illegal practices in our processes (terrorism, illegal trade, drugs traffic, etc.)
Ø Fulfill all the legal requirements in our processes
ABB
Our Zero Defects Objectives
ZD does not mean that we will not have failures, it meansthat we will not be happy with any failure!
Quality ISO 9001
100% OTD
Zero TestFailures
100% Customer Satisfaction
H U A C A L T A N Q U E
C O N S E R V A D O R
PROTECCION
AISLADORES
H U A C A L
R A D I A D O R E S
OHSAS 18001
Zero Lost DayIncidents
Environ. ISO 14001
Zero Oil Spilling
QHSE Objectives
Zero COPQ
Zero ElectricalEnergy Waste
BASC
Zerocontamination
Quality ISO 9001
100% OTD
Zero TestFailures
100% Customer Satisfaction
H U A C A L T A N Q U E
C O N S E R V A D O R
PROTECCION
AISLADORES
H U A C A L
R A D I A D O R E S
Quality ISO 9001
100% OTD
Zero TestFailures
100% Customer Satisfaction
H U A C A L T A N Q U E
C O N S E R V A D O R
PROTECCION
AISLADORES
H U A C A L
R A D I A D O R E SH U A C A L T A N Q U E
C O N S E R V A D O R
PROTECCION
AISLADORES
H U A C A L
R A D I A D O R E S
OHSAS 18001
Zero Lost DayIncidents
Environ. ISO 14001
Zero Oil Spilling
QHSE Objectives
Zero COPQ
Zero ElectricalEnergy Waste
BASC
Zerocontamination
The Quality Strategy
1. Philip Crosby´s – QIT – Quality Improvement Process:
n Quality School
n Quality Improment Team
n Zero defects philosophy
2. Integration QHSE + BASC
Philip Crosby
Quality Improvement Process launchingsince
2002
Quality School´s principle:
“The Competence and Consciousness of our employeesare our greatest assets”. BA PPTR Mnger.
since
2002 Quality Improvement Process launching
since
2002 Quality School launching
Quality Class Room
QS: Every body talking same languaje:QS: Every body talking same languaje: Quality!Quality!
u Quality Throughout Work Team (QTWT)
Each Improvement Project1000 USD Savings
Course for Blue collars Course for Blue collars (15 Hours in 6 weeks)(15 Hours in 6 weeks)
Each Improvement Project1000 USD Savingsuu Quality Education Quality Education
System (QES)System (QES)
Course for White collars Course for White collars (25 Hours in 10 weeks)(25 Hours in 10 weeks)
Course for Managers Course for Managers –– QIT QIT (12 Hours in one weekend)(12 Hours in one weekend)
Course to get internal Quality Instructors Course to get internal Quality Instructors
since
2002 Quality School strucutre
EMC:
ü General Manager
ü Quality Manager
ü Controller
ü Logistic Manager
ü Human Resource Manager
ü Engineering Manager
ü Production Manager
ü Marketing Manager
ü Supply Manager
ü Order Handling Manager
Quality Improvement Teamsince
2002
The QIT in 2002. Today it has 10 membersand they meet each two weeks with thefollowing agenda…
Basic Cyclic Agenda
Quality Improvement Team
NCR DistributionTransformersAudit ReportsSix Sigma &
dpmo’s5S and
Housekeeping
NCR PowerTransformers
EnvironmentalManagment
System –
Follow up toQHSE Objectives
Metalshopsupplies
Follow up
OHSAS 18001Training Program& Quality School
Quality ActionPlans on going
ManagmentSystems´
Integration
CCRP
and
CustomerSatisfaction
Balance ScoreCard
Quality Performance
Index
Improvement Projects
- QS -
4th Meeting3th Meeting2nd Meeting1st Meeting
In each session at least three of this topics are reviewed
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 review
5. 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
QHSE + BASC Certifications
ISO 9001
since 1996
ISO 14001
since 1999
OHSAS 18001
since 2005
BASC
since 2006
BELIEFS
SYSTEM ISO 9001, ISO 14001, OHSAS 18001, BASC, etc
PROCEDURES MP, TI, Manuals, etc.
BEHAVIORS
VALUES
TraditionalFocus
World ClassFocus
Certifies are not enough to be World Class
STRUCTURE Resources
By Abraham Maslow (1908 – 1970)
QHSE Management evolution
The Integral Employee
knows, wantsand has will
power!
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 Systemacc. to SA 8000 Standard
DATEDESCRIPTION
Next steps