QUALITY PLAN
POWER TRANSFORMERS MANUFACTURING
CUSTOMER: SIDOR C.A.
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*
SUPPLY
MNGMNT.
HUMAN
MNGMNT.
INFORMATION
SYSTEMS
INTEGRAL
QUALITY
MNGMNT.
FINANCIAL
CONTROL
MAINTENANCE &
GENERAL
SERVICES
SUPPLIERS
C
U
S
T
O
M
E
R
S
SERVICE
* Mutual Interaction
COMMUNITY
STRATEGIC MANAGEMENT
Code: F01- MGIPTG001 PROCESS
LEADER OBJECTIVE
SUPPLIER INPUT
SUB 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 parties Certifier 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 Simulations Equipments and devices of measurement and
monitoring calibrated / verified Records
Equipped Classrooms Internal auditors
Process of Improvement of the Integral Quality
Computing Equipments QIT/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
Planning of the Mgt. System
Activities of the Processes Operational Controls Practices of response before
Emergencies Residues of the Processes Information of Security of Chemical
Products Equipments of following up and measurement (It includes software
when necessary) Mgt. System Processes
Customers
Operational control and Response before Emergencies
Legal conformity
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 PAPTQ003 PAPTQ004 PAPTQ005 PAPTQ013 PAPTQ027 PAPTQ028 ITPTQ006 - 008 ITPTQ010 ITPTQ015 ITPTQ035 ITPTQ037 - 039 Manager of PTQ Assistants of PTQ Process managers Technician Laboratory of Oils
Operators Suppliers 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. Chemical Prod.
Management Tools
Code:
F01- MGIPTG001
PROCESS
LEADER
OBJECTIVE
SUPPLIER
INPUT
SUBP
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
Design for Offers
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
Electrical design for
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
Designers
Planning
Record Meeting SUM
Plan of Invoicing
Technical specifications
Mechanical design for
production
Plans of Manufacture
Technical Support
PTD
PTP
PTO
Review and Control
of Changes
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
Remainders
Chemical Prod.
Critical Com.
Legal Reg.
Management Tools
Measurement and Monitoring
Measurement and Monitoring
Enviromental Asp.
Dangers and Risks
Management Prog.
Code: F01- MGIPTG001 PROCESS
LEADER OBJECTIVE
SUPPLIER INPUT
SUBP 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 planning
Process control
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 Tests
PTS PTE
Transformer ready for shipping
Registration in BaaN PTO
Readying and
Operative Shipping
ITPTP038 ITPTP045
Leader and Operators of Assembling and Shipping Released Transformer for Shipment
Packaging Packing List Warehouse
Standard and customized materials, approved, and minor raw
materials Winding manufacture 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 Windings
Sub process of Assembling and Connections
PTS Sub processes of Cores, Windings and Warehouse
Windings Core Clamps Switch Plans/Designs
Active Part Assembly
ITPTP026 ITPTP009 ITPTP044
Leader and Operators of
Assembling Active part assembled and connected Sub process of cubing
Core Manufacture
ITPTP003 ITPTP008
Leader and Operators of
Assembling Verticalized 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
Tanking and Final Assembly
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 tests General information of Tests
Final Test PAPTQ002, ITPTQ011, ITPTQ012, ITPTQ014, ITPTQ016 - ITPTQ022 ITPTQ032
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 resources Operator 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 Windings Equipment 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. Critical Com. Managment Tools Critical Com.
