Sr No Observation

1 Manufacturing Plan and Material Requirement plan is not available in document

2 Plan vs Actual is not available to track the Manufacturing loop holes

Quality checklist not available to track the quality of product due to which mistakes are
3 getting repeated

4 Root Cause Analysis part is missing due to poor Quality Management System

Overall equipment effectiveness is missing to maintain the effectiveness of new

5 equipments and reduce the maintainance cost

6 Standard Operating Procedure for each KV class and MVA is not there for any process

No checklist for vapour phase drying process and no proper document is available with
7 full details

Final assembly of 330KV transformer will be a problem as Lifting equipment Like JLG is
8 not available
Drawings for 330KV is out dated with lot of brazing and copper tube which can be
9 replaced with modern desin with cables and crimping. So for that crimping tools need to
be procured
Lean Manufacturing environment is missing in the factory, clean production is also
10 missing in the factory

11 Safety standards are not followed properly

12 Tracking of Cost and Delivery is missing and there is no inventory control technique

Movement of product in shop floor is not visible, utilization of factory is not going on
13 properly

Movement of 330KV transformer into Test Lab is a constraint as the test lab door width
14 is less

15 Modification of tools, equipments and Oil Processing system need to be done

16 Modification required for the aeration of Hedrich VPD with Dry Air Generator

17 Mc Leod Gauge and Pirani gauge to be procured for measureent of vacuum

18 Special adopter need to be designed for vacuum pulling and hot oil circulation

19 Torque wrench of specified value not available

20 Available tools are not calibrated

21 New belts,slings,I Bolt and D Shackles need to be procured

22 GOST standards required in english language and russian language for study

Proper meeting need to be done for 330KV,125MVA Transformer with

23 design,production,quality and Procurement department and top management for each
process
Training need to be imparted to technicians as 330KV, 125MVA is a manufactured first
24 time in ATEF
Remarks
Sr No Tools Required Remarks

1 Core Building Table

1 Weight of Core 53.2 T
2 Weight of Winding assembly each phase
3 Weight of Tertiary Winding
4 Weight of Regulating Winding
5 Weight of MV Winding
6 Weight of HV Winding
7 Weight of Active Part 87 T
8 Weight of full assembly with oil 188T
9 Transport Weight (without Oil) 111T
10 Weight of Oil 59 T