Quality Planning and Analysis for Power Generating Transformer Design and Maintenance

UTS: ENGINEERING
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Assignment # 1
“Quality Planning and Analysis”
Power Generating Transformer
Design and Maintenance
DEVELOPMENTCOMPANY – ABC PVT. LTD

1.0 Executive Summary
ABC private limited is an Australian Company; plans to market launch its
new range of power transformers to compete in the energy market,
where scarcity of number of power generating transformers is
noticeable. Ever growing population and demand for 24 hours power
supply generates the demand for high end transformers. Every electricity
production and supply company is nowadays looking for energy
generating low cost transformers. The entire new project is based on
production lines and maintenance of the sold transformers. Initially the
market launch will be done with observation period of 18 months, and
then the maintenance section will start putting tenders and quotations.
The mobile transformers will be launched first between the proposed
three lines of variants. The company has conducted extensive market
research with the aim of producing products and following the ISO 9001:
2015 standard: This report describes the complete description of the
query and the planning of the company.

Table of Contents
1.0 Executive Summary........................................3
2.0 Introduction.............................................6
2.1 Significant role of transformers in the Energy supply
chain.......................................................7
3.0 Customer satisfaction....................................8
3.1 Stakeholder Analysis:...................................8
3.2 Capturing needs of the customers.......................11
3.2.1 Surveys............................................11
3.2.2 Focus groups.......................................11
3.2.3 Complaints.........................................11
3.2.4 Customer visits....................................12
3.2.5 Interviews.........................................12
3.3 Analysis of customer needs (KANO Analysis)............12
4.0 Design Requirements.....................................16
4.1 Customer needs being translate into design requirements
(QFD):.....................................................16
4.2 Design Risk Analysis (FMEA)............................18
5.0 Supplier evaluation and selection:......................19
5.1 Identification of components...........................19
5.2 Setting up of criteria for Supply chain................20
5.3 Construction of Supplier choice model..................21
5.4 Report.................................................21
6.0 Statistical process control.............................22
6.1 Identification of procedures...........................22
6.1.1 Design.............................................22
6.1.2 Selecting suppliers and cost sign off:.............22
6.1.3 Inspection of supplier’s products:.................22

6.1.4 Defect Inspection:.................................23
6.1.5 Testing:...........................................23
6.1.6 Distribution procedures:...........................23
6.1.7 Marketing products:................................23
6.2 Using SPC charts for monitoring:.......................23
6.21 P-chart:............................................24
6.22 NP chart:...........................................24
6.23 C -Chart:...........................................24
6.24 U-chart:............................................24
6.25 X-chart:............................................24
6.3 Construction and usage of SPC chart:...................25
6.4 Explanation............................................26
7.0 Problem solving.........................................27
7.1 Identification of problem solving tools:...............27
7.2 Usage and construction of problem solving tools:.......28
7.2.1 Brainstorming:.....................................28
7.2.2 Causes:............................................28
7.3 Why-Why Analysis.......................................29
7.4 Cause- and –effect diagram.............................29
7.5 Pareto Analysis........................................30
8.0 Conclusion..............................................31
9.0 References..............................................32

2.0 Introduction
Power transformers have the capacity to transfer power with the help of
electromagnetic induction usually at the same frequency having different
currents and voltages. Generally power distribution and transformation in
daily life is performed by the transformers. At the time of transferring
power to long distances, power transformers act as a supportive bridge.
It has been found that in the absence of power transformer transmission
of voltages to different locations leads to uncanny situations. So it is
always recommended to adopt a power transformer at the time of long
distance power transmission. The use of power transformers is largely
dependent on the power demands. It can be said that power distribution
as well as transmission is not possible without the use of power
transformers (Blanco, 2009). The initial power transformers are of 1500
KVA capacity. In future, the load amount of the transformers will be
increased up to 2500 KVA.
2.1 Significant role of transformers in the Energy supply chain
The company is thinking on production of few power transformers which
are in demand in the current market. The features that are associated
with full range transformers proposed by the company are mentioned
below:
 HVDC Transformers
 Shunt reactors
 Auto Transformers
 Mobile Transformers
 Large and medium sized power transformers
 Phase shifting transformers
 Track side Transformers

Usually two or more coils are wrapped in and around a magnetic
material in a transformer. Transformers react differently in relation to AC
and DC currents. For example: DC current can pass through the
transformer without encountering any change in the wires however AC
current cerates significant impact upon the wires. As the current passes
into one coil then flow to another coil does hamper. Transformers are
able to understand the need of voltage by checking on the turning of the
coils (Borucki, Boczar & Cichoń, 2011). Voltage can be defined as
energy per charged particle and current is defined as the flow of charge
per second. There is a direct correlation between voltage and current
flow. With the increase in the voltage, there is a significant increase in
the flow of current. Alternating flux is known to produce an alternating
current and the flux varies so as to ensure self-induced emf that is found
across winding. This system works in accordance with Faraday’s law of
electromagnetic induction. It can be discerned that supplied voltages act
as cause and emf is its effect. As per Lenz’s affect works in opposition to
cause. Self-induce emf is highly dependent on supplied voltage and not
on the number of turns taken by coil (Borghetti at al., 2009).
3.0 Customer satisfaction
3.1 Stakeholder Analysis:
The stakeholder analysis has been performed in a planed way (Reed et
al., 2009). The Australian company proposes to take note of all the
stakeholders and satisfy their needs and demands in near future. The
stakeholder analysis has been done and represented in tabular format.
All the stakeholders, starting from government to contractual workers,
have been taken into account. In the last financial year the company

received various acclamations for heavy industrial power backup
generators. The plan of modelling and commercial production of the
power transformers was undertaken last year only. The marketing team
has done a market survey to build a core team of engineers. In the first
phase the mobile transformers will be marketed. In the second phase,
company plans to launch its maintenance team with categorical
engineering team. Following table has been generated for stakeholder
analysis (Prell, Hubacek & Reed, 2009).
Table 1: Details of the stakeholders of power transformers
Stakeholders Requirements
Internals
Higher Administration
More proficient items with minimum conceivable
cost
Minimum misfortunes
Reliability
Long-enduring creation
Increased creation and supply
Reputation
Government
Low support
Cheap profitability with positive yield
Long-term unwavering quality
Cheap and powerful assembling
Investors and Sponsors More wage with higher intrigue