Embed Size (px)
Citation preview
ABB Power Quality Products
Management System Overview
ABB Group
ABB is a global leader in power and automationtechnologies that enable utility and industrycustomers to improve performance while loweringenvironmental impact. The ABB Group of companiesoperates in around 100 countries and employs about107,000 people.
ABB Power Quality Products
ABB Power Quality Products is based in Charleroi,Belgium.
Thanks to an extensive experience and use of thelatest technologies, ABB develops, designs andmanufactures amongst other products a compre-hensive range of products and solutions thatimprove the power quality of the Low VoltageNetwork by eliminating disturbances and improvingpower factor.
ABB Power Quality Products is the ABB center ofexcellence for this activity. Its business integratesR&D, manufacturing and marketing at a worldwidelevel.
ABB Power Quality products are sold in more than70 countries with extensive local engineering andexpertise.
ABB Power Quality Products is the worldwideleader in Low Voltage Power Quality.
Our products/solutions portfolio is organizedaround 3 main application fields:
Reactive power compensation
LV capacitor units type CLMD and LVCS.
Power factor controllers type RVC and RVT.
Automatic capacitor banks with and without reactorstype APC.
Flicker control
Thyristor switched capacitor bank type Dynacomp.
Harmonic mitigation
LV Active Filters type PQFK, PQFI, PQFM, PQFS.
2 ABB Power Quality Products
Management System
The Power Quality Products Unit of ABB runs anintegrated management system for quality,environment, safety and security.
Mastering processes and how they interact withone another is the prerequisite for effective andefficient economic activity. We are continuouslyimproving our performance in managed learningcycles.
Our documentation principle and every process areclearly and succinctly described in the ManagementManual.
Our processes are presented in the form offlowcharts and stored with all internal instructionsin our document management system. This docu-mentation is available to all employees and isbinding for all of them.
Quality
Our quality management system has been certifiedaccording to ISO 9001 since 1993.
Main attention is focused on our customers. Inorder to satisfy the customers, we find out whattheir expectations are and support them with ourproducts in our fulfilling their strategic objectives.
Environment
Our environmental management system has beencertified according to ISO 14001 since 1997.
Careful handling of natural resources is one of ourgoals. Minimizing the use of raw material forproducing and reducing the waste are the otherones. We have implemented procedures to recyclean important part of our wastes.
Safety and Security
In 2004 we obtained OHSAS 18001 certification forthe safety at work and health protection parts ofour safety and security management.
We bear responsibility for the safety of ourworkforce at their workplace.
To reduce the risk of accidents, we follow someindicators like frequency rate or gravity rate.
Laboratories
Our laboratory plays an important role in productdevelopment. It is part of CSA program (CategoryCertification Program). This means that we arecertified to perform tests, according to CSA, on ourproducts.
3ABB Power Quality Products
Policy and Objectives
ABB Power Quality Products regards customer satisfaction as its principal objective.
We strive to deliver products with optimum qualityand accept our responsibility towards futuregeneration by taking account of economic,ecological and social aspects in equal measure.
Continuous Improvement
In order continuously improve our processes, wehave implemented a systematic approach that isbased on different proven methods in the domainof the quality. This method, called 4Q, follows thefollowing steps:
1. Measurement and collection of data
Before collecting the data, the quality managerconsults the database “Cost of Power Quality”. Thissystem collects all costs of quality issues. It enablesus to find the real origin of important problems.
2. Data analysis
- Brainstorming in order to answer somequestions (who, what, where, when, how, why,how many).
- Classification of results following the 5M method(Manpower, Machine, Measurement, Method,Milieu) to obtain the Ishikawa Diagram.
- To find the real causes of the problem, we usethe 5 Whys method.
3. Search for solutions and action plan
4. Verification of effectiveness and formalization ofthe actions
4 ABB Power Quality Products
Satisfaction of our customers
Our customers’ expectations and requirements areof decisive importance for us and play a key rolein the improvement of processes, products andservices.
Global CCRP (Customer Complaint ResolutionProcess) is an integrated method for managing bothexternal and internal complaints. Capturing,resolving and analysis of complaints will for usresult in satisfied customers and informationindicating where we need to make processimprovement. This program allows our customersto log their complaints over the Internet themselvesand to be advised of our actions.
We inform our customers about the environmentaland safety aspects of our products in conjunctionwith their operation, maintenance and disposal.
Moreover, our employees are empowered toidentify customer’s needs and to translate them intohigh-quality products and services.
Commitments of the Suppliers
We undertake active supplier management withevaluation and assessment of suppliers. We needto have raw materials and outsourced parts thatmeet our requirements.
To select a new supplier, we evaluate his financialsituation, his environmental and quality system andhis technical resources. We send him one ques-tionnaire reviewing all these aspects. We can alsoperform an audit.
Most of the time, we require a measure certificateand a declaration of conformity with our deliveries.Besides that a panel of deliveries is inspectedvisually and/or by measurement. If we refuse aproduct, the quality department issues a rejectionnote. All these notes are analyzed during theevaluation process.
Twice a year, we run an evaluation of three typesof suppliers: key suppliers (for raw material criticalfor production), suppliers with quality problemsand one supplier by article group.
The quality and the logistic scores give us the finalscore by supplier. The results are published in themanagement review and sent to the concernedsuppliers. If one supplier has a score lower than50% in quality and/or in logistic or a final scorelower than 60%, we contact him to take correctiveactions. We can also decide to stop our partnership.
In order to optimize the entire process, we alsoinvolve suppliers at the early stages of productdevelopment and process optimization. Our projectmanagers work closely with them for this purpose.Cooperation is fixed in frame agreements.
5ABB Power Quality Products
Organization and Training
ABB Power Quality Products has a suitable orga-nization and a dedicated workforce with thenecessary qualifications to fulfil their tasks, therebyensuring that requirements regarding processes andproducts are met.
Organization
Our internal organization is part of the quality, envi-ronmental and safety and security organization ofthe ABB Group.
Every week the management reviews quality, safetyand environment issues. There is also a weeklyquality meeting for each production line and onespecific meeting between quality and maintenancemanagers.
Training
The requirements as to the various functions aredefined in terms of quality, environment and safety.All new employees receive their training plan withthese different parts.
Supplementing a range of external training oppor-tunities, ABB offers an extensive in-houseprofessional training program for developingtechnical, social and management skills. Eachemployee begins to work with an experiencedcolleague. The training duration varies accordingto the function (2 weeks for the marking, 4 monthsfor metallization).
During annual meetings with employees, therequirements for professional training are gauged,any necessary action and training courses areplanned, and the implementation of training ischecked.
6 ABB Power Quality Products
Process and ProductPerformance
ABB Power Quality Products develops manufac-tures and inspects its products according to definedprocesses.
Product management is responsible for the productsfrom the development stage right through to theirrecycling and disposal. It is also responsible forour product portfolio.
Product development is structured into variousphases, with a defined release procedure in placebefore the transition from one phase to the next.Product management, handling, service and materialmanagement are involved at an early stage.
The IPE (elements) production followsthe steps below:
Metallization
Large rolls of Polypropylene film are metallizedwith a thin layer of metal. The process is realizedunder vacuum conditions.
Slitting and winding
The rolls are then cut into smaller ones. Thisprocess as well as the winding is performed in aroom with controlled atmosphere.
Two metallized films are wound together with asmall displacement to allow for contacting. Thefinal diameter of the active part of the element isdefined at this stage and depends on the elementrating.
Contact spray and clearing
Metal is sprayed on the edges of the winding. Afterthe spraying process, elements are mechanicallycleaned and an increasing voltage is applied to thewinding to clear any small defect in the capacitordielectric.
Soldering
Connections wires are soldered to the element
7ABB Power Quality Products
Thermal treatment
The elements are thermally treated under vacuumto improve life and dielectric characteristics.
Marking
We encapsulate the elements and mark them fortraceability.
PU filling
A capacitor winding may suffer from contact withair and humidity. The can is thus filled withpolyurethane resin to ensure a perfect seal.
Final test
All capacitor elements are subject to a stringentroutine test with test parameters chosen at or abovethe requirements of applicable internationalstandards. Before final packing and labelling, theelement is again inspected.
The LVCS production is fully automaticand realized by robots.
In a first step, the protection device is automaticallyassembled. To ensure uniform quality there areseveral fully automated test and verification station.A camera and image recognition system does, forexample, verify the correct positioning of the inter-ruption device.
Welded and soldered contacts are verified inelectrical tests. Appropriate testing of the dielectricsystem (current, voltage, tangent δ, capacitance) isperformed on both component and final assemblylevel. Bar codes are used for traceability.
8 ABB Power Quality Products
Robots also assemble discharge resistors and testthem. The terminals and the discharge resistors arewelded on the element. After that the enclosure isfilled with polyurethane to ensure a perfect seal(also automatically verified).
At the end, we test all products (polyurethane level,exposed conductive parts, rigidity, capacity andtangent δ, discharge resistors, etc).
Assembly of all other products
IPE and LVCS are assembled with other componentsaccording to technical drawings of our otherproducts: capacitor banks, controllers, Dynacompand active filters.
Quality assurance carries out inspections and grantsreleases during production. All inspections to beperformed up to the customer acceptance aredefined in quality plans. We use the SPC system(Statistical Process Control) to control our processes.
Inspection and testing equipment is monitoredaccording to a documented procedure.
Using appropriate process measurements for quality,environment and safety and security, we evaluateour processes, detect any deviations (Capabilityprocess, Capability machine…) and define the needfor corrective and preventive measures.
9ABB Power Quality Products
Auditing and Reviewing of theManagement System
The management system for quality, environmentand safety and security is audited and reviewedtwice a year with objective of achieving continuousimprovements.
Auditing
Our management system is audited twice a year inaccordance with ISO 9001:2000 and OHSAS18001:1999 and annually for ISO 14001:2004 by anaccredited certifying body.
In addition, we perform environmental and safetyand security inspections of our sites in the presenceof external experts.
In accordance with our internal planning, qualifiedinternal auditors check all our processes on a regularbasis in internal audits. Potential for improvementand corresponding actions are logged and auditreports are submitted. The quality managermonitors that the improvement measures are carriedout. Information gained during audits is used forevaluating the management system.
Review
In January and in July, we evaluate the effective-ness and efficiency of the management system in amanagement review. This system of two reviewsallows us to adapt our methods for best perfor-mances.
The management review report evaluates the qualityof our system, raw materials, suppliers, products,customer satisfaction, resources management,environment and safety with regard to continuousdevelopment and attainment of objectives duringthe previous year. It also contains a forecast forinternal audits. Moreover, objectives are set for thecoming year.
The Management accepts the report and commu-nicates the new objectives to the workforce.
10 ABB Power Quality Products
11ABB Power Quality Products
2G
CS
90
10
11
A0
00
© Copyright 2006 ABB n.v. Power Quality Products
ABB Power Quality ProductsAvenue Centrale, 10Zoning Industriel de JumetB-6040 Charleroi (Jumet), BelgiumPhone: +32 71 250 811Fax: +32 71 344 007
www.abb.com/lowvoltage
