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ABB Power Quality Products

Management System Overview

ABB Group
ABB is a global leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 107,000 people. Our products/solutions portfolio is organized around 3 main application fields: Reactive power compensation LV capacitor units type CLMD and LVCS.

ABB Power Quality Products


ABB Power Quality Products is based in Charleroi, Belgium. Power factor controllers type RVC and RVT.

Automatic capacitor banks with and without reactors type APC.

Flicker control Thyristor switched capacitor bank type Dynacomp. Thanks to an extensive experience and use of the latest technologies, ABB develops, designs and manufactures amongst other products a comprehensive range of products and solutions that improve the power quality of the Low Voltage Network by eliminating disturbances and improving power factor. Harmonic mitigation ABB Power Quality Products is the ABB center of excellence for this activity. Its business integrates R&D, manufacturing and marketing at a worldwide level. ABB Power Quality products are sold in more than 70 countries with extensive local engineering and expertise. ABB Power Quality Products is the worldwide leader in Low Voltage Power Quality. LV Active Filters type PQFK, PQFI, PQFM, PQFS.

ABB Power Quality Products

Management System
The Power Quality Products Unit of ABB runs an integrated management system for quality, environment, safety and security. Quality Our quality management system has been certified according to ISO 9001 since 1993. Main attention is focused on our customers. In order to satisfy the customers, we find out what their expectations are and support them with our products in our fulfilling their strategic objectives. Environment Our environmental management system has been certified according to ISO 14001 since 1997. Mastering processes and how they interact with one another is the prerequisite for effective and efficient economic activity. We are continuously improving our performance in managed learning cycles. Our documentation principle and every process are clearly and succinctly described in the Management Manual. Our processes are presented in the form of flowcharts and stored with all internal instructions in our document management system. This documentation is available to all employees and is binding for all of them. Careful handling of natural resources is one of our goals. Minimizing the use of raw material for producing and reducing the waste are the other ones. We have implemented procedures to recycle an important part of our wastes. Safety and Security In 2004 we obtained OHSAS 18001 certification for the safety at work and health protection parts of our safety and security management. We bear responsibility for the safety of our workforce at their workplace. To reduce the risk of accidents, we follow some indicators like frequency rate or gravity rate.

Laboratories Our laboratory plays an important role in product development. It is part of CSA program (Category Certification Program). This means that we are certified to perform tests, according to CSA, on our products.

ABB Power Quality Products

Policy and Objectives


ABB Power Quality Products regards customer satisfaction as its principal objective. We strive to deliver products with optimum quality and accept our responsibility towards future generation by taking account of economic, ecological and social aspects in equal measure. Continuous Improvement In order continuously improve our processes, we have implemented a systematic approach that is based on different proven methods in the domain of the quality. This method, called 4Q, follows the following steps: 1. Measurement and collection of data Before collecting the data, the quality manager consults the database Cost of Power Quality. This system collects all costs of quality issues. It enables us to find the real origin of important problems. 3. Search for solutions and action plan 2. Data analysis Brainstorming in order to answer some questions (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 use the 5 Whys method.

4. Verification of effectiveness and formalization of the actions

ABB Power Quality Products

Satisfaction of our customers Our customers expectations and requirements are of decisive importance for us and play a key role in the improvement of processes, products and services. Global CCRP (Customer Complaint Resolution Process) is an integrated method for managing both external and internal complaints. Capturing, resolving and analysis of complaints will for us result in satisfied customers and information indicating where we need to make process improvement. This program allows our customers to log their complaints over the Internet themselves and to be advised of our actions.

Commitments of the Suppliers We undertake active supplier management with evaluation and assessment of suppliers. We need to have raw materials and outsourced parts that meet our requirements. To select a new supplier, we evaluate his financial situation, his environmental and quality system and his technical resources. We send him one questionnaire reviewing all these aspects. We can also perform an audit. Most of the time, we require a measure certificate and a declaration of conformity with our deliveries. Besides that a panel of deliveries is inspected visually and/or by measurement. If we refuse a product, the quality department issues a rejection note. All these notes are analyzed during the evaluation process. Twice a year, we run an evaluation of three types of suppliers: key suppliers (for raw material critical for production), suppliers with quality problems and one supplier by article group.

We inform our customers about the environmental and safety aspects of our products in conjunction with their operation, maintenance and disposal. Moreover, our employees are empowered to identify customers needs and to translate them into high-quality products and services.

The quality and the logistic scores give us the final score by supplier. The results are published in the management review and sent to the concerned suppliers. If one supplier has a score lower than 50% in quality and/or in logistic or a final score lower than 60%, we contact him to take corrective actions. We can also decide to stop our partnership. In order to optimize the entire process, we also involve suppliers at the early stages of product development and process optimization. Our project managers work closely with them for this purpose. Cooperation is fixed in frame agreements.

ABB Power Quality Products

Organization and Training


ABB Power Quality Products has a suitable organization and a dedicated workforce with the necessary qualifications to fulfil their tasks, thereby ensuring that requirements regarding processes and products are met. Organization Our internal organization is part of the quality, environmental and safety and security organization of the ABB Group. Every week the management reviews quality, safety and environment issues. There is also a weekly quality meeting for each production line and one specific meeting between quality and maintenance managers. Training The requirements as to the various functions are defined in terms of quality, environment and safety. All new employees receive their training plan with these different parts.

Supplementing a range of external training opportunities, ABB offers an extensive in-house professional training program for developing technical, social and management skills. Each employee begins to work with an experienced colleague. The training duration varies according to the function (2 weeks for the marking, 4 months for metallization). During annual meetings with employees, the requirements for professional training are gauged, any necessary action and training courses are planned, and the implementation of training is checked.

ABB Power Quality Products

Process and Product Performance


ABB Power Quality Products develops manufactures and inspects its products according to defined processes. Product management is responsible for the products from the development stage right through to their recycling and disposal. It is also responsible for our product portfolio. Product development is structured into various phases, with a defined release procedure in place before the transition from one phase to the next. Product management, handling, service and material management are involved at an early stage. The IPE (elements) production follows the steps below: Metallization Large rolls of Polypropylene film are metallized with a thin layer of metal. The process is realized under vacuum conditions. Slitting and winding The rolls are then cut into smaller ones. This process as well as the winding is performed in a room with controlled atmosphere. Contact spray and clearing Metal is sprayed on the edges of the winding. After the spraying process, elements are mechanically cleaned and an increasing voltage is applied to the winding to clear any small defect in the capacitor dielectric. Soldering Connections wires are soldered to the element Two metallized films are wound together with a small displacement to allow for contacting. The final diameter of the active part of the element is defined at this stage and depends on the element rating.

ABB Power Quality Products

Thermal treatment The elements are thermally treated under vacuum to improve life and dielectric characteristics.

Final test All capacitor elements are subject to a stringent routine test with test parameters chosen at or above the requirements of applicable international standards. Before final packing and labelling, the element is again inspected.

Marking We encapsulate the elements and mark them for traceability. PU filling A capacitor winding may suffer from contact with air and humidity. The can is thus filled with polyurethane resin to ensure a perfect seal. The LVCS production is fully automatic and realized by robots. In a first step, the protection device is automatically assembled. To ensure uniform quality there are several fully automated test and verification station. A camera and image recognition system does, for example, verify the correct positioning of the interruption device.

Welded and soldered contacts are verified in electrical tests. Appropriate testing of the dielectric system (current, voltage, tangent , capacitance) is performed on both component and final assembly level. Bar codes are used for traceability.

ABB Power Quality Products

Robots also assemble discharge resistors and test them. The terminals and the discharge resistors are welded on the element. After that the enclosure is filled with polyurethane to ensure a perfect seal (also automatically verified).

Assembly of all other products IPE and LVCS are assembled with other components according to technical drawings of our other products: capacitor banks, controllers, Dynacomp and active filters.

At the end, we test all products (polyurethane level, exposed conductive parts, rigidity, capacity and tangent , discharge resistors, etc).

Quality assurance carries out inspections and grants releases during production. All inspections to be performed up to the customer acceptance are defined in quality plans. We use the SPC system (Statistical Process Control) to control our processes.

Inspection and testing equipment is monitored according to a documented procedure. Using appropriate process measurements for quality, environment and safety and security, we evaluate our processes, detect any deviations (Capability process, Capability machine) and define the need for corrective and preventive measures.

ABB Power Quality Products

Auditing and Reviewing of the Management System


The management system for quality, environment and safety and security is audited and reviewed twice a year with objective of achieving continuous improvements. Auditing Our management system is audited twice a year in accordance with ISO 9001:2000 and OHSAS 18001:1999 and annually for ISO 14001:2004 by an accredited certifying body. In addition, we perform environmental and safety and security inspections of our sites in the presence of external experts. In accordance with our internal planning, qualified internal auditors check all our processes on a regular basis in internal audits. Potential for improvement and corresponding actions are logged and audit reports are submitted. The quality manager monitors that the improvement measures are carried out. Information gained during audits is used for evaluating the management system. Review In January and in July, we evaluate the effectiveness and efficiency of the management system in a management review. This system of two reviews allows us to adapt our methods for best performances. The management review report evaluates the quality of our system, raw materials, suppliers, products, customer satisfaction, resources management, environment and safety with regard to continuous development and attainment of objectives during the previous year. It also contains a forecast for internal audits. Moreover, objectives are set for the coming year. The Management accepts the report and communicates the new objectives to the workforce.

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ABB Power Quality Products

ABB Power Quality Products

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Copyright 2006 ABB n.v. Power Quality Products

www.abb.com/lowvoltage

2GCS901011A000

ABB Power Quality Products Avenue Centrale, 10 Zoning Industriel de Jumet B-6040 Charleroi (Jumet), Belgium Phone: +32 71 250 811 Fax: +32 71 344 007