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STRATEGIC MANAGEMENT
LOGISTIC
C U S T O M E R S
C U S T
O M E R S
COMMUNITY
SUPPLIERS
SUPPORT PROCESSES*
SUPPLY MNGMNT. HUMAN MNGMNT. INTEGRAL QUALITY MNGMNT. INFORMATION SYSTEMS MAINTENANCE & GENERAL SERVICES FINANCIAL CONTROL
* Mutual Interaction
Matrix SGI
Critical Com.
Legal Reg.
Enviromental Aspects
Management Prog.
Management Tools
Integral Quality Management Integral Quality Manager 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.
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 Planning of the Mgt. System MGIPTG001 NTC ISO 9001:2000 NTC ISO 14001:2004 NTC OHSAS 18001:2000 NEZCP061 NEZCP045 NEZCP046 NEZCP060 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
Activities of the Organization Changes to the New Processes or Modifications of the Requisites
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
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)
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
ITPTQ001 - 002 PAPTQ006 - 007 - 008 - 009 - 010 PAPTH002 - 003 Manager of PTQ PAZCC022 Assistants of PTQ PAZCH015 - 016 Process managers NEZCP063 - 064 - 065 Technician Laboratory of Oils ITPTQ040 - 041 - 042 Operators PAPTQ003 Suppliers PAPTQ004 Contractors PAPTQ005 Visitants PAPTQ013 Engineer Room of Tests PAPTQ027 Users of equipments / PAPTQ028 devices ITPTQ006 - 008 ITPTQ010 ITPTQ015 ITPTQ035 ITPTQ037 - 039
Records of Operational Control Quality records Record of Evaluation of Simulations Equipments and devices of measurement and monitoring calibrated / verified Records
Legal conformity
NEZCP046
To keep the program: School of the Quality Quality School BA PTPR 1LAA000022 To coordinate the activities of Continuous Improvement and QIT Manager of PTQ Manager of PTH
Competent and Careful Personnel Minutes of the QIT Plans of Action Records of Continuous Improvement
PT Division
Requisites of Mgt. System Contract with Certifier entity Reports of previous Audits Indicators of management
NEZCP026 NTC ISO 9001:2000 NTC ISO 14001:2004 NTC OHSAS 18001:2000
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
MANAGEMENT OF RESOURCES HUMAN RESOURCES PTQ Manager (Representative of the Direction for Mgt. System) Equipped offices QIT/Managing Boards Assistants of Integral Quality Internal auditors Brigade of Security Coordinators of Evacuation OHS committee Computing Equipments Information Technology Resources (Intranet, internet, databases: SSA, CCRP, Borwin, CRS) Room of Metrology Equipped Classrooms Room of conferences with audio-visual aids (video beam, VHS, TV and projector) Brigade Location Nursing station RESOURCES OF INFRASTRUCTURE
Audits
Matrix SGI
Chemical Prod.
Critical Com.
Legal Reg.
Enviromental Asp.
Management Prog.
Management Tools
F01- MGIPTG001 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.
SUPPLIER
INPUT
SUBP
ACTIVITY
DOCUMENTS
RESPONSIBLE
OUTPUT
CLIENT
Planning
PTO
PTO
Technical norms Technical specifications of the Client Price Database Technical instructions of BA
To prepare a Pre-design
Designers of Offers
Technical Offer
PTM
Technical specifications of the Client Technical and Commercial offer Technical norms Technical instructions of BA
ITPTE002 - ITPTE009 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
Electrical Designers
Cards of Manufacture Plans Electrical design Structure of Materials Data for Tests Technical Support
Technical specifications of the Client Technical and Commercial offer Technical norms Technical instructions of BA Electrical Design
ITPTE002 - ITPTE009
Mechanical Designers
To review, to verify and to validate the Electrical and/or Mechanical Design PAPTE004 PAPTE002 To control changes of Electrical and/or Mechanical design
New Designs
PTP PTD
MANAGEMENT OF RESOURCES HUMANS Manager of Engineering Electrical Design Engineer Mechanical Design Engineer Equipped offices Computing Equipment (computers, printer and plotter) Information technology resources (Intranet, Internet, software of design, database BA) INFRASTRUCTURE
Matrix SGI
Chemical Prod.
Critical Com. Critical Com. F01- MGIPTG001 Power Transformers Production Manager
Legal Reg.
Enviromental Asp.
Managment Prog.
Managment Tools
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
SUPPLIER
INPUT
SUBP
PARTICULAR ACTIVITIES
DOCUMENTS
RESPONSIBLE
OUTPUT
CUSTOMER
Process control
Product in Process Criteria of Acceptance Sigma Cards Cards of Program of Manufacture Plans / designs General Schedule Macro planning
To prepare isolations Winding manufacture To paper conductors To wind To dry and to press Windings To dry and to press Windings Core Manufacture 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
Warehouse
ITPTP004, ITPTP005, ITPTP006, ITPTP024, ITPTP025, ITPTP026, ITPTP036, ITPTP039, ITPTP043, ITPTP046
Block of Windings
ITPTP003 ITPTP008
Verticalized 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
Active connected part Tank Accessories Processed and proved oil Plans/Designs
PTP PTE
Transformer released by Room of Tests, Protocols of Tests, Minutes of Controlling, Reports of Feedback to the Design
Final Test
Sub process of Room of Tests Released Transformer for Shipment PTS Packaging PTE Packing List
To test airtightness, to dismantle external accessories, to do identification and marking, to coordinate their packaging
ITPTP038 ITPTP045
PTO
MANAGEMENT OF RESOURCES HUMANS Manager of Production Planner of Production Supervisor of Production Operator of Insulations Assistant of Windings Assistant Assembly Windings Paper Operator Leader of Windings Plant of manufacture of Power transformers Equipped offices Computing equipment Information technology resources (Intranet, Internet, databases, BaaN System)Recursos informticos (Intranet, Internet, Bases de Datos, Sistema BaaN) Room of Tests for transformers of Potency and Laboratory of Oils Teams of safety and personal protection Equipment for the handling of heavy loads 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 Financial resources INFRASTRUCTURE
Operator Windings Operator Assembly Windings Assistant of Assembling Assistant of Materials Assembling Leader Operator of Oils Wiring Operator Operator of Connections Operator of Shipments Operator of Cubing and Final Assembly Operator of Cores and Active Part Chief of Room of Tests Operator Laboratory PTP Technician of Laboratory of Oils
QHSE Management
Internal Auditors
QHSE - BASC
Quality
Carlos Ossa
H&S
M. Marn L. Montoya
Environmental
Paula Mesa
BASC
Samuel Zuluga
Test Processes
JCV JM - HV
SPT TR
DTR TR
Oil Analysis
ABB
1990: ABB Group arrives to Pereiras factory through a global acquisition of Westinghouse T&D segment 1996: Quality Management System is certified with ISO 9001 by BVQi 1999: Environmental Management System is certified with ISO 14001 by BVQi 2002: Philip Crosbys Quality Improvement Process is implemented
QIT: Quality Improvement Team is established with the local Top Management QS: Quality School program is launched to give all people trainin in Quality issues, technical competence and to encourage their Quality Awareness
2003: Six Sigma tool is implemented for TrafoStar power transformers 2005: Occupational Health and Safety Management System is certified with OHSAS 18001 and the 3 Management Systems are integrated in QHSE 2006: BASC Managemen System is certified by the WBO (Business Alliance for Secure Commerce)
6
5 4
ISO 9001
3 2 1
ISO 14001
QIP
1996
1999
2002
2005 2006
2009
On Time Delivery
Customer Satisfied
Greater EBIT
Best prices
QHSE and BASC Policy (Translation) Do well our work since first time to get Customer's Satisfaction by means of Quality Products and Quality Services delivered on time, producing the budgeted profitability.
To get this, our commitment is:
Promote people's Competence and Awareness as our greatest asset To rise the life's quality of our employees by means of the continuous improvement in H&S issues Reduce waste generation and natural resources consumption in our processes Improve continuously our Processes efficacy Prevent illegal practices in our processes (terrorism, illegal trade, drugs traffic, etc.) Fulfill all the legal requirements in our processes
OHSAS 18001
Zero Lost Day Incidents
BASC
Zero Electrical Energy Waste Zero contamination
ZD does not mean that we will not have failures, it means that we will not be happy with any failure!
ABB
1.
2.
e sinc 2002
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Quality Schools principle: The Competence and Consciousness of our employees are our greatest assets. BA PPTR Mnger.
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EMC: General Manager Quality Manager Controller Logistic Manager Human Resource Manager Engineering Manager Production Manager Marketing Manager Supply Manager Order Handling Manager The QIT in 2002. Today it has 10 members and they meet each two weeks with the following agenda
2nd Meeting
Quality Performance Index
3th Meeting
Balance Score Card
4th Meeting
CCRP and Customer Satisfaction
Metalshop supplies
5S and Housekeeping
Audit Reports
Resources ISO 9001, ISO 14001, OHSAS 18001, BASC, etc MP, TI, Manuals, etc.
Next steps
Implement Social Responsibility Management System December /08 acc. to SA 8000 Standard Integrate QHSE + BASC + SR Columbian Quality Management Award Iberoamerican Quality Management Award December /08 December /08 December /09