This document discusses quality assurance and control processes for transformers. It is divided into two sections: incoming material quality and process quality assurance. For incoming materials, items are checked against standards and substandard items are rejected. For process quality assurance, various transformer production steps like tank manufacturing, painting, winding, and assembly are verified through check sheets and visual/measurement inspections. Suggestions are provided to improve productivity, such as using carbide blade tips to increase core cutting production and installing separate gas lines to resolve oven temperature issues.

1. PRODUCTIVITY
ENCHANTMENT
INCOMING AND PROCESS QUALITY ASSURANCE
MR. M RIZWAN

2. QUALITY CONTROL AND ASSURANCE
It can be divided into two sub category
• Incoming Material Quality
• Process Quality

3. INCOMING MATERIAL QUALITY
• Material Received in our premises from different vendors is to be checked on the
basis of WAPDA Standards and our Drawings.
• These inspections are performed by visual inspection and measurements i.e.
vernier caliper, screw gauge, Conductivity Meter, Resistivity Meter, etc.
• Sub standard Material is Rejected and returned to vendor.

4. PROCESS QUALITY ASSURANCE
Transformer Tank Manufacturing Section
Verify the Check sheet of
 Tanks
 Top Plates
 Core Channels
By visual inspections and measuring tools.

5. PROCESS QUALITY ASSURANCE
Transformer Paint Section
 Verify the Check Sheet of
 Tank Paint Quality
 Top Plates Paint Quality
By visual inspections and Paint Thickness Meter.

6. PROCESS QUALITY ASSURANCE
Transformer Winding Section
• Verify the Check Sheets of
• LT Windings
• HT Windings
By visual inspections and measuring tools.

7. PROCESS QUALITY ASSURANCE
Transformer Core Cutting Section
Verify the Check Sheets of
• Core Slitting
• Core Cutting
By visual inspections and measuring tools.

8. PROCESS QUALITY ASSURANCE
Transformer Core Stacking and CCA Section
Verify the Check Sheet of
• Core Stacking
• Core Coil Assembly
By visual inspections and measuring tools.

9. PROCESS QUALITY ASSURANCE
Transformer Connections Section
Verify the Check Sheet of
• LT Connections
• HT Connections
By visual inspections and measuring tools.

10. PROCESS QUALITY ASSURANCE
Transformer Tanking Section
Verify the Check Sheet of
• Final Assembly
By visual inspections and measuring tools.

11. MACHINE PRODUCTIVITY ENHANCEMENT
Core Cutting Presses
• Currently these presses are working on MS type Blades that need to be sharpen
2-3 times in a day, which lost almost 1 hr. of production.
Improvement:
• If we shift to Carbide Tip Type Blades which need to be sharpen almost after 2
months, resulting in the increase in production about 6~8 % in a day.

12. MACHINE PRODUCTIVITY ENHANCEMENT
Transformers Heating Ovens
• Heating ovens temperature issue due to low Bio Gas Pressure.
Improvement:
• Separate Bio Gas Line for each Burner / Oven for resolving Pressure issues to be
installed which can enhance heating oven productivity.
• It can be automated and temperature data can be stored which will decrease its
maintenance cost.