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Switchgear Manufacturing

1. DESIGN & ENGINEERING PROCESS

1.1 New Order

After receiving an order, project file which includes Contract,technical specifications and Scope of supply etc. is given to Design & Engineering Manager for review and project planning.

Design & Engineering manager assigns one Electric Design engineer who is going to handle this project. Project file is also checked by Electric Design engineer.

1.2 Project Kick-Off

To Design & Orderhandling from Bid & Proposal :
Contract,technical specifications, Scope of supply and technical data sheet are handed over Electric design engineer.

1.3 Switchgear Designing & Engineering

Switchgear design starts by ;

- Ensuring that selected components and materials fulfil the requirements of technical Specification ;

- Clarifying the mechanical dimensions ( Size of modules, cubicles, main busbars,..etc.).

In generall, prepared electrical projects are sent to customer for approval. After getting approval, all material orders could be given. Due to the risk no purchase orders should be placed until customer approval has been given.

Approval period ( preparing electrical projects + correspondence with customer } could be from 2 weeks up to 6 weeks.

Detailed design is made based on preliminary design that comes from Bid & Proposal.

The approximate product mixture in Turkey is as below :

- 40% Fixed Modules

- 15% W-Modules, Plug-in Modules

- 20% Direct connection to BB Modules ( In > 800 A )

- 25% AC Drives, Soft starters, Capacitor banks.

When any revision request comes from customer, it should be checked technically by Electric Design engineer. If applicable, Sales gives change order offer to customer.

1.4 Material Orders

Purchase order of electrical components are given by Electric Design engineers.

Purchase & Manufacturing order of mechanical parts are given by Mechanical Design engineers.

1.5 Completing the documentation

Customer documentation consist of :

Index, Placement list, Module list, List of apparatus,

Front view of Switchgear, Single line diagram, Control circuit diagram, List of interconnection cables and List of control cables.

Project bound, Logistics &MWS & Assembly documentation consist of :

Purchase Requests, Mechanical part list, Mech. part drawings, MWS work orders, Assembly drawings, technical data sheet, Factory check-list Picking list is prepared for purchased items and given assembly so that they can take those materials from store.

Index, Placement list, Module list, List of apparatus, Front view of Switchgear, Single line diagram, Control circuit diagram, List of interconnection cables and List of control cables.

1.6 Supporting the production

When internal manufacturing or assembly have difficulties to understand projects or to find some materials etc., Design give them help.

1.7 Preparing the `as-built `documentation

After factory routine tests, necessary revisions are made on electrical projects.

As tested drawings are sent to customer.

Non-confirmance reports are closed.

1.8 Progress Reporting

Actual and forecasted design load are monitored on capacity plans.

Status of material receipts is reported weekly by logistic dep.

1.9 Tools and Methods

AutoCAD could be used for front views and single line diagrams as well as all mechanical part and assembly drawings.

EPLAN is advised for Control Circuit Diagrams.

An ERP software should be used for material planning ,issuing order request and Design and Labor hours.

1.10 Target

To reduce design hours.

2. PRODUCTION PROCESS

2.1 Mechanical production planning

Weekly meetings are arranged between Design&Engineering and Internal manufacturing.

According to assembly schedule, it is explained when assembly needs steel and copper parts for each project.

2.2 Assembly kick-off

Before assembly starts, there is a meeting between Design&Engineering and assembly. Design engineers prepare project file and hand it over to Assembly foreman.

2.3 Clarifying the availability of Materials

2.3.1 Purchased materials;

Material follow-up for purchased materials are handled by Logistics.

2.3.2 Consumable materials;

Foreman follows consumables. 3-bin method could be used for consumables. 1-bin is in store and 2-bin are kept in floor stock. When one of them is finished, foreman gives it to store and takes 1 full bin. Store has to order 1-bin material.

2.3.3 Internal manufacturing ( Own manufactured parts ) ;

Sheet Steel, polycarbonate, copper parts and text labels can be manufactured internally.

2.4 Assembling

Assembly starts in accordance with schedule if material availability is clarified.

In the process of assembly, modules and switchgear are visually checked according to factory checklist.

In case of having defective, missing or wrong materials and indefiniteness in documentation, foreman informs Assembly manager.

2.5 Progress Reporting

Actual and forecasted Assembly load are monitored on capacity plans.

2.6 Testing (Routine Factory Test)

QC department performs routine tests according to the factory checklists. If any fault is diagnosed, it is written on fault list and this list is sent to Design&Engineering .

After completing tests, test certificate is issued by QC.

2.7 Packing & Delivering

Before delivery, packing list is given by Electrical Design Engineer to Project Manager for invoicing and preparation of shipment documentation.

2.8 Tools and Methods

ERP

Factory checklist & Manufacturing instructions for assembling and testing

Tools for assembly

2.9 Target

To reduce assembly hours.

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