Electrical Transformer Manufacturing Process
The highest quality standards are built into every Waukesha® transformer, whether it is manufactured in Waukesha, Wisconsin, or Goldsboro, North Carolina. The company has earned ISO 9001:2008 certification (Waukesha, Goldsboro) and has a reputation for quality and reliability that is among the best in the industry. Complying with the SPX Transformer Solutions Quality Policy is the overriding objective and primary responsibility of every employee, meaning that every unit we build and deliver to our customers has been manufactured to provide consistent performance, dependability and long service life. With nearly 15,000 power transformers installed, the facts speak for themselves:
- One of the lowest incidences of through-fault failure
- Low maintenance due to advanced design
- Long contact life LTCs
- Certified accuracy of loss measurement
- And many other benefits!
OUR MANUFACTURING PROCESS
OUR QUALITY POLICY
Our primary responsibility is to safely provide outstanding products and services that exceed the expectations of our customers by continually improving our processes, performance and products.
QUALITY MANAGEMENT SYSTEM
Our corporate objective is Total Customer Satisfaction and we have structured our quality system so that all completed units meet individual customer specifications and industry standards. To deliver the consistent quality transformers and power equipment that our customers demand, both of our manufacturing operations have
- Trained quality specialists and testers on all shifts
- Several hundred test and measurement items on a rigorous calibration program
- Online non-conformance system to resolve issues before a unit ships
OUR QUALITY SYSTEM COVERS EVERYTHING FROM CUSTOMER REQUIREMENTS TO SHIPPING
Customer Requirements and Specifications
To be sure that our plant and facilities are prepared to meet customer specifications, a systematic review is performed to identify each condition of purchase, including special requirements. This allows ample time for preparation in the event that special test or inspection equipment is required.
Since purchased items and raw materials must meet design requirements and specifications, our Quality and Global Sourcing Groups work as a team to select only those suppliers capable of delivering materials and products that consistently meet SPX Transformer Solutions quality, manufacturing and technical demands. Performance requirements are defined and documented for applicable material specifications, engineering instructions and standards data. Our measurement and corrective action systems are functioning to continually improve the quality of supplier products and services.
Once suppliers have been selected, all incoming production materials are subjected to receiving verification. Material not consistent with expectations and specifications is segmented and prevented from use in our manufacturing facilities. A documentation system provides a history of part characteristics and supplier performance.
Manufacturing and Assembly Operations
To confirm that all components and subassemblies manufactured at SPX Transformer Solutions meet design specifications, a documented system of inspection of critical dimensions and attributes takes place at the point where each component is manufactured. This prevents nonconforming components from entering the main transformer assembly bay or supporting assembly operation. The inspection system provides for the identification, segregation and disposition of all nonconforming parts and/or assemblies.
Engineering Change Requirements
When changes are made, the Quality team is continually provided with up-to-date computerized Engineering Change Notices to be sure that all components and assemblies are manufactured with the most current engineering information.
Waukesha® transformers must pass an extensive series of standard inspections and electrical tests, including impulse and Corona tests — conducted according to IEEE and other standards. Additional information can be found in our Transformer Testing section.
Prior to release by manufacturing of a completed transformer, a thorough inspection is made. Specific shipping details requested by the customer are checked,along with essential transportation and vehicle requirements. Working together with the customer, our Quality, Manufacturing and Engineered Shipping groups work as a team to provide accurate, on-time and damage-free delivery of each Waukesha® transformer.