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Preface
Foreword On the strength of its experience, Schneider Electric has always sought to produce hight quality equipment, fully complying with IEC 60439-1 standard. But what exactly do we mean by Quality ? The standard ISO 9000 denes the quality as: degree to witch a set of inherent characteristics fulls requirements Although nal inspection is in some respects a statement of failure (as we have not been able to control the necessary quality throughout the assembly process) it is nevertheless a vital stage in equipment production. This stage must be performed with care and rigour, both with respect to customer specications (explicit needs), and proper operating procedures (implicit needs), in order to satisfy the customer. The quality is also the willingness of all the staff, from the manager to the worker to satisfy the customer. This guide is a good means to help you in this way and to reach the excellence.
Contents
Quality inspection: means and process Introduction to the quality inspection 1.1 Justication of quality inspection 1.2 Quality inspection function 1.3 Quality inspection responsibility 1.4 Quality inspectors prole 1.5 Necessary documents 1.6 Required human resources Incoming delivery inspection 2.1 Justication of the incoming inspection 2.2 Procedures In process inspection 3.1 Inspection during manufacturing 3.2 Justication of the inspection during manufacturing stage 3.3 Process 3.4 Means Final inspection 4.1 Final inspection process 4.2 Operating rules 4.3 Non conformity treatment process 4.4 Conformity declaration Quality inspection: instructions Performing in-process inspection 5.1 Reminder 5.2 Composition 5.3 Process Performing the nal inspection 6.1 Conformity check 6.2 Mechanical checks 6.3 Electrical operations checks 6.4 Prior dispatching checks Summarising of nal inspection operations 7.1 Comprehensive list of points to be checked Summarising of tasks after nal inspection stage Quality inspection: follow up Quality dashboard 8.1 Purpose 8.2 Principles 8.3 Produced non quality 8.4 Example of a Produced Non Quality index board 8.5 Non conformity weight example
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Contents
Quality inspection: facilities and calibration Facilities 9.1 The Quality Inspectors individual tools 9.2 Common means of the quality inspection 9.3 Quality inspection zone 9.4 Necessary documents Control of inspection means 10.1 Purpose 10.2 Reminders of basic principles 10.3 Responsibility 10.4 Diagram of operations 10.5 Application rules Quality inspection: appendix Follow-up of missing parts Form example Checking program Non quality record board Corrective action request Final inspection record Missing parts list Glossary Abreviations Vocabulary
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Procedure Set of organisational rules of an administrative nature in order to achieve a certain result Specied way of accomplishing an activity (see ISO 9001).
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b inspection of the assembly b dielectric tests and / or measurement of insulation resistance b checking of protective measures and of the electrical continuity of the protective circuit.
Human factors
The specicity and complexity of low voltage equipment, the numerous human interventions, and thus risk of errors are the principal source of mistakes in our eld, so the main reasons of the implementation of the quality inspection process.
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Cost reduction
The non quality manufactured entails extra cost in term of time and money due to: b product examination b reparation b scrap b incidence in term of delivery schedule, brand image b etc. A study shows that a fault detected on customer site can cost one hundred to one thousand times more than if it had been detected during the switchboard design phase (see graph below). The in process checking operation and the nal inspection also guarantee
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Applicable to the external and internal goods or assembly. In the case of sub assembly or internally manufactured goods, an internal procedure could be used to perform a nal inspection of one process, joined to the incoming inspection of another one.
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2.2 Procedures
Verication
The quantity and aspect control of goods could be done by the receiving agent. The quality checking should be done by the quality inspector. In case of large volume of goods, this operation could be done on a sample. All the incoming goods should be received and stored in such condition that they will not be damaged till their nal installation.
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In process inspection
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3.3 Process
The inspection during manufacturing stage could be described by the following process: b inspection during manufacturing stage This operation consists in carrying out checks at different stage of the assembly process v systematic inspection or sampling which is part of quality inspectors responsability v inspection done at the end of each key manufacturing step such as cubicle assembly, devices adaptation, functional units assembly... N.B.: non conformity treatment is the same as the one described in the nal inspection chapter.
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In process inspection
b continuous inspection The assembly operations requires constant carried out of the professional rules. Due to that, this procedure consist of carrying out checks throughout manufacturing in the form of operators or project supervisor check. It will make them responsible for the quality of their work. These check should always be validated by the nal inspection inspectors. Notice: integral part of the checking operations, the cleaning process should be performed during and at the end of the manufacturing process and registered on the check list. (i.e.: Okken or Blokset busbar compartment).
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3.4 Means
Presented as a check list form (could be a part of the nal inspection check list), the instructions provided at each manufacturing stage enable these checks to be formally dened. One check list is commonly dedicated and located on the cubicle frame, other check lists can be done for functional units or manufacturing operation done apart from the cubicles. The tter should ll in the check list to allow the quality inspector to verify that all the points are checked and that the procedures are implemented. b these follow-up sheets are used to log the status of the inspections performed. The same forms are nally authenticate by the quality inspector during the nal inspection stage. N.B.: Despite the operator checks performed for each operation, nal inspection is always necessary. As it is stipulated by standard IEC 60439.1.
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Final inspection
Final inspection guarantees operation and conformity of products with respect to applicable drawings and standards. It is performed by the units quality inspection department. A document per project formulating the customers requirements and transcribing the specication is used for the checking phases during assembly and for nal inspection. It forms the rst reference document (production le). The following table gives you an idea of the average time required to perform a nal inspection according to the type of switchboard to be inspected. The following information is given in average % of assembly process.
Simple switchboard PCC MCC 3% 4% Semi-complex <X> <X> Complex 8% 10 %
b carry out the conformity check b conduct the tests b modify the production file by adding any necessary annotations (throughout testing) b list all the non conformities: v by noting all the faults or modifications observed v by drafting a list of missing parts. Ensure reworking for conformity. b if customer acceptance is scheduled, receive the customer and / or his representative in the quality inspection zone. Sign the nal inspection report after customer acceptance. b point out any areas of dispute between customer and supplier b ensure that the design documents have been properly corrected, by checking final version status and updating b ensure that all the check list is filled in b draft and record the final inspection report b sign the final inspection report and other documents b archive the documents.
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Final inspection
b. mechanical checks These checks consist of testing proper operation of the mechanisms and manual controls, the sturdiness of the switchgear, etc. c. electrical checks b operating tests b dielectric withstand b electric continuity of protection circuits b insulation resistance.
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Final inspection
During the nal inspection operations, any errors detected must be recorded on an non quality record board and all non conformities corrected. E.g. : type of table. Non quality record board Location / BB Type of fault assembly Cabling error Busbar support missing b Corrective action Performed Time by Jean 5 min Alain 1 hour
Cabling b
Signature
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Final inspection
DATE: ...././. Job n: ....... Switchboard: Cubicle: . Equipment n / location: Rating: .. Design n:
Conformity Mechanical check Electrical test Dielectric test Protective measures check Insulating test Index:
Only fully inspected cubicles can be dispatched. A label, resembling the one below, is used to identify them before packaging.
Final inspection sheet Ready for dispatch Client: Switchboard designation: ... Final inspection report n: ... Quality Inspector Name: Signature: Date: ......./......./....... Purchase order n Design le reference ... Issue on: Quality Manager Name: Signature:
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PE50640
Instruction (dictionary denition) Verbal or written explanation intended for the person responsible for the carrying out of a specic mission.
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5.1 Reminder
The purpose of in-process inspection is to ensure product conformity after each manufacturing operation. This process concerns all the manufacturing operations done by the workshop operators.
5.2 Composition
One assembly follow-up check list sheet is completed for each cubicle and / or functional unit (according to the manufacturing process). This document is used both by the operators and the quality inspectors (see follow up check list example in the appendix). It is used from the rst assembly phase through to nal inspection. This check list should mention: b the designation of each point to be controlled b the operator identification and the checking period.
5.3 Process
After each stage, the operator checks and declares product conform by signing this follow up check list sheet and noting any observations. On completion of the inspections, a copy of this sheet is archived.
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b take delivery of the switchboards to be inspected in the dedicated zone b become acquainted with the project production file b check the observations and information given in the assembly followup sheet (could be a part of the follow up check list) b perform the final inspection by using the follow up check list.
Appearance
Paint colour and reference Use the colour palette to ensure that the reference of the paint given in the project le matches the colour of the cubicle. Verication generally carry out at the incoming delivery inspection stage. Homogeneity Perform a visual inspection to check the homogeneity of the colours of the various switchboard components (doors, panels, etc.). Finishing Check external appearance by a visual inspection: no scratches, deformations, etc. Front face and mimic diagram b visually check that the front face of the switchboard matches the one shown in the drawing of the project b check conformity of the mimic diagram compared with the power diagram and front lay out.
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6.1.2 Framework
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Framework
Panelling b operation of doors, mechanical accessories and drawers: v check their operation by manoeuvring them v ensure that the cubicle equipment is complete and has been installed properly b ensure the presence, characteristics (IP, material...) and proper fitting of: v ventilation grid, bottom plate v side and rear cover v roof, blanking plate, etc. b conformity of cut outs in the plates: Using the drawing, check the presence of any cut outs in the roofs, mounting plate and separation plates allowing sh plating, coupling bars installation, interlock cables or rods installation, etc. Checking the locks Check matching of the lock references and the key numbers with the references given in the project production le. Mechanical assembly Check the overall assembly, frame position (top, bottom), the presence and location of the screws required for assembling and joining the cubicles, bottom plate, mounting plate, etc. Check that all screws, picot washers and earth braids (if required) for xing these components are present, and check that screws are properly tightened. Ground xing Use the project design drawing to check the location of the ground xing points. Handling devices Check their xing and their disposition according documentation. Cable routing area Check the special facilities provided for cable (top or bottom) routing or bus way links. b fixing of mounting plates, protection screens and partitioning or cowling parts: v check that all the screws for fixing these parts are present, and properly secured v check the quality of the riveted assembly, type of rivets, direction, pressure. Check the connection facilities space and equipment Checking the degree of protection: b this check is performed by checking the presence of the components guaranteeing the IP level stated in the project production file. Needs vary according to the required IP degree: awning, seal, front plate, cable glands, etc. (information given in the product catalogues or guides). If a seal is used, ensure it is properly positioned and continuous b be sure that the IP degree of the equipment located on the door or the device manoeuvring mode (cut out on doors or presence of specific cover), matches with the switchboard requirement.
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6.1.3 Switchgear
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Conformity of devices
Location / identication Use the layout diagrams in the project production le to ensure that the devices are properly located and identied (QF1, QF2, etc.). At the same time, the nature of the labels associated with the devices and the content of the text can be checked. Characteristics b devices characteristics: v type, rating v breaking capacity and number of poles v Masterpact terminal pads characteristics and installation (according product). Inspection to be done prior the installation in the cubicle (Inspection during manufacturing process). Check or carry out the settings such as thermal and magnetic releases, time delays, etc. b associated devices Check presence and technical data of circuit breakers associated devices (Vigi, fault signal switch, trip unit, etc.). Check the supply voltages for: v switchgear motor mechanisms v coils (contactors, relays, impulse relays, under voltage or shunt coils of the Compact, Masterpact and multi 9) v indicator lights v all the electronic devices v soft started, capacitor bank.... b torods Check the technical data of each torod, their compatibility with the customer connection cables. Also ensure the correct mounting direction: the arrow shows current direction. b current transformer v check the technical data of the current transformers together with the installation direction v check the correspondence between the current transformer and the associated device, ammeter, etc. Ensuring that the current delivered by its secondary circuit is compatible with the associated device v check the respect of the clearances between the fixing and the secondary connecting screws of the current transformer versus live conductors or metal parts. Check if the current transformer are well secured on the conductor. Shunt Check the connection between the shunt and the measuring instrument. Safety perimeters Check the circuit-breaker safety perimeters referring to their installation guides. No devices, equipment or bundle should be located in the safety perimeter. Accessories Visual checking of the presence of : b crank handles for circuit-breaker and / or drawers extraction b doors stop, light b clamps for fuse extraction b pins for fixing certain relays b etc.
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PE50649
Accessibility
Accessibility of functional units or devices Check accessibility of: b the terminal, current transformer, etc. Always check the ease access of: v pivoting front face locking devices. If stipulated in the project specications, check also the access facilities for thermography control.
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Installation and maintenance access Check accessibility of: b joint, cubicle coupling accessories b settings, HPC fuses for replacement, contactors coils, interlocking mechanism, arc chute chamber. In some particular case, (e.g. plug in auxiliary terminal block), check the ease of removing them from their support in regards of the screws access for modications and maintenance. The associated bundle should be long enough to have access to the screw without difculties.
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Busbar
Type and characteristics Check the bars characteristics according to the type of equipment, the project specications, the project design. b cross-section: according to nominal current (In), short-circuit current and / or peak current, IP, circuit-breaker breaking time, etc. Check that the cross-section corresponds to that shown in the project production le and product documentation. b coating: check the type of busbars coating (bare copper, tin-coated, sheathed busbars, epoxy paint, silver-plating, nickel, etc.). Marking and phase order b check phase labelling type conformity b check that phase order (phases 1, 2, 3, neutral and PE) is respected according to the product specifications. Layout and installation b check their position (horizontal, vertical, top, etc) b check that the layout or arrangement of the busbars does not obstruct the routing of client cable b ensure the extension possibilities of the busbars according to specific features b spacing, fastening, characteristics and number of busbar supports. Refer to technical documents, switchboard characteristics, etc. b type of supports: v check their type and characteristics (material) referring to the switchboard characteristics v check the alignment of the support, presence of deformation due to extra torque apply on the fixing bolt. Bending radius and bar alignment a minimum bending radius must be respected that is equal to r = 1.5 x e. If the copper is of excellent quality (Cu ETP), we accept: r = e. Check the perfect alignment of the different bar assembly: b ensure a good positioning in the support b make easier the insertion of the connection bolt b avoid trouble (flexion, torsion...) on devices or terminal pads connections. Busbar joints Joints cross-section Characteristics and number Check positioning and accessibility of the joints screws Insulating distances versus frame, form partition, etc. Cleanness After busbars installation, ensure that no foreign body are lost in the bars compartment. In particular in the case of access difculties. According to the installation system and the procedure in use, this verication should be authenticate using the check list.
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Flexible bars Characteristics Cross-section To be checked according to the device and switchboard characteristics. Installation Radius of curvature of the exible bars (at least once bar thickness). Bending manual operations are recommended to avoid damage on the bar insulator. In the event of a superimposed exible bar installation, ensure that insulating spacers are placed between the conductors to provide proper ventilation. Binding Check that the characteristics and number of bindings used matches with the electro-dynamic force supposed to affect the assembly in case of short circuit. No direct binding on metal parts. If necessary t an insulating wedge. Check the connections: presence of the thick at washer and the contact washer.
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Wiring in cable trunking: b maximum cable size 6 mm in cable trunking. Ensure that the reserve in the cable trunking is approximately 30 % and that their fasteners are preferably made of insulating accessories (e.g. polycarbonate screws or rivets). b the maximum centre distance between two trunking fasteners must not exceed 600 mm. Non protected active conductors Ensure that the cable not protected by short circuit devices are installed safely throughout their entire way. Bundle separated, no risk of mechanical damage, safe connection, etc.
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The following table gives the inspections to be performed according to the type of connection used: b where A, B, C stand for the various inspection types. A = visual inspection B = mechanical inspection C = checking presence and positioning.
Connections Jaws and auxiliaries pins Lugs Clips Cable connectors Terminals Screws Power A+B A+C A B+C C Other circuits A+B B+C A+B B B C
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Connection stresses and fastening Check that the lugs match with the connector type. Be sure that the cable are well inserted in the terminal. Remind: make sure that the crimping tools are calibrated. Accessibility and client connections facilities Accessibility of power connection points on devices, and terminal blocks: b within the respect of the cable curvature radius, of the cable routing way (entry from the top / bottom) b by checking the length of pads and number of connecting holes in consideration with the size and number of cables (check the devices or product information). Check that: b the number and cross-section of cables ensure compliance with clearances (lugs) Remind: arrange it on the way to ensure the safety of the operators (maintenance). b the number and sturdiness of the cable supports b the ease of connection of client cable on earth or PEN bar nearby the functional unit.
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When the devices are link to terminals or pads, perform the tests on them. Checking the control circuits Check the power supply of the auxiliary circuits by examining phase order at their associated control devices. Remind: a particular attention should be done on the non protected circuit (see chapter 7.5.5 IEC 60439-1). Electrical indicator light and command button: b check the function of the indicator lights b ensure the correspondence of the command button with associated devices. Remote / local operating mechanisms: b check their operation. If necessary use accessories (pin tip, small box equipped with pushbuttons, indicator lights, etc.). Supply circuits: b systematically check the electronic switchgear supply circuits and the DC circuits using a tester (voltmeter).
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DD383189
Check the information supplied on the connection terminals: b contact status b remaining information (voltage, current, etc.). Motor mechanisms Close the relevant protection devices. Activate the operating mechanism of the devices according to the command diagram, local, remote, automation... Electrical locking Check that it is impossible to close a device equipped with a locking contact. Metering circuits Check the winding direction, the inlets and outlets characteristics of the current transformers. To check the metering circuits, the CT secondary must be supplied using a phase shift box (failing this, you can use any other calibrated device offering the same possibilities). b example of carrying out the operations: v select the supply voltage v adjust the maximum value of the current to be injected in the secondary circuit v inject the current in one of the circuits or in all three at once to check cabling. Checking the test function Circuit-breaker operation is checked by a variety of tests according to device type: b earth leakage module test (Multi 9 range, NS range): v close the circuit-breaker v press the test button of the Vigilohm part. This test is used to regularly check device tripping by simulating an earth fault b trip unit test (NS and Masterpact range): this test is performed using an external electronic tripping box v close the circuit-breaker v make it trip using the box by connecting its cord to the specially provided socket on the front face of the trip unit part v for increased dependability, repeat this operation. If the circuit-breaker opens for each test, the device operates correctly. Voltage relays, time delay relays, fault tracking devices For the voltage relays, check that the contacts are in the status dened in the electric design. For the time delay relays, check correct operation of the time delays. If mentioned, check that these settings comply with the project design le. For the fault tracking devices, create a fault and check that the device detects and indicates its presence. In order to create a fault, a resistance box can be supplied: b pre-set the value of the resistance required to create a fault according to fault tracking devices characteristics b make the resistance vary by reducing its value. When the resistance is adjusted below the pre-set value, the device must indicate the fault.
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Second routine test Protective measures & protective circuit 6.3.2 Protective measures and electrical continuity of the protection circuits (standard IEC 60439-1 paragraph 8.3.3)
Monitoring protection circuits
DD383168
The inspection is either visual and / or electrical as required by the customer. Mechanical inspection (Visual) PE and / or PEN protection bars. Check the presence of all the constituent elements of the assembly which guarantee the electrical continuity between the metal part and the earth bar (see technical le). Cross-section in accordance with electrical characteristics. Presence and cross-section of the joints between the cubicles, they should be at least equal to the cross-section of the PE / PEN bar to be connected. Depending of Earth/Neutral link systems, check presence of the PEN / PE disconnecting link and access. Ensure that its cross-section is the same as that of the earth bar.
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Check b that the protective conductors are identified by the two colours green / yellow marking plus PE or PEN lozenges b the accessiblility of the terminals for external conductors b the contact efficiency between section or parts of the protective circuit b the presence of only one conductor per connection on the protective bar. If, for maintenance reasons, a part of the equipment is removed from the enclosure, the protective circuit of the other parts should not be interrupted. Electrical inspection N.B.: There is some electrical measuring devices enable to perform this test. The above method is given only for information. Example of operating mode: b a DC source is used, with an electromotive force of less than 6 V / 2 A current is injected between the inlet of the earth busbar and the parts to be inspected (doors, front face, frame, etc.)
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Result: b the inspection is satisfactory if the measured resistance between the circuits and exposed conductive parts is below 0.1 Ohm. Register the result on the nal inspection record list
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PE50656
Third routine test Dielectric test 6.3.4 Dielectric withstand (Standard IEC 60439-1 paragraph 8.3.2)
Dielectric test
Preparation The dielectric test is always performed before the insulation test. Before performing the test, make sure that you disconnect: b the surge absorbers (if any) b the covers from the Vigi modules of the Compact NS b the electrical control motors b and any other device not withstanding the applied voltage (electronic switchgear, contactor coils, indicator lights, miniature relays, horn, measuring instruments, etc.). The interference suppression capacitors installed between the live parts and the frames must not be disconnected, but be able to withstand the test voltage. This test does not need to be made on auxiliary circuits which are connected to the main busbar if it: b is protected by a device of rating < 16 A b has previously undergone the operating tests (IEC 60439-1 chapter 6.3.2). N.B.: Check that no unprotected connections are left. For example: remove the neutral connection wire for the permanent insulation measurement. Operating mode Perform this test using a dielectrometer (or dielectrimeter) designed to deliver a variable voltage 0-5000 V AC. Voltage to be applied:
Main circuit Rated insulation voltage Ui Dielectric test voltage 2500 V 300 V < Ui y 690 V 800 V < Ui y 1000 V Auxiliary circuit Ui y 60 V Ui > 60 V 3500 V 1000 V (2 Ui + 1000) V with 1500 V min.
Apply voltage in turn on each phase and on the other phases which are inter-connected and brought back to the switchboard frame. The standard stipulates that this test voltage must be maintained for one second. N.B.: If, for any reason, the dielectric test must be repeated, it will be done with voltage lowered to 85 % of the previous value. Carrying out the operations Example of the phase live part test: b all switching devices shall be closed b interconnect the exposed conductive parts and earth them b interconnect the live parts to one another and then to the assembly conductive parts b connect the measuring instrument earthing wire to the assembly frame b connect the injection cable to the circuit to be monitored and gradually increase voltage up to the required value
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b the test voltage should be applied for 1 second b gradually reduce voltage before disconnecting b once this check is complete, repeat it for the other live circuits. Result The tests are satisfactory if there is no puncture or ashover. Register the result on the nal inspection record list
6.4.1 Cleaning
Prior the packing, check that the equipment is clean: b no dust b no foreign body forgotten in the equipment. Remind: See chapter 3.2 about the assembly for witch the access is difcult at the nal inspection stage.
6.4.2. Miscellaneous
From a detailed check list establish by the design ofce, perform the inspection of: b all the equipment to be delivered separately, spare parts, devices dismantled for transportation, etc b roof, coupling screws b busbar joints, etc.
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Documentation Presence of the name plate and / or the as built design. Make sure that all the documentation associated to the quality inspection procedure are full: b missing part list b final inspection report b checking program b corrective action form b non quality record board b delivery note b etc. Associated documentation delivered with the equipment: b devices and switchboard technical documentation b maintenance documentation b missing part list and on demand b final inspection report. Be sure that all internal devices or other parts are well secured, inserted or locked in the switcboard
6.4.3. Packaging
Inspection of the packaging before delivery according to: b the type of good to be carried b the transportation means b the destination b the condition of storage b the climate conditions.
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General informations
Product: .........................................................................................................................................................................
Client reference:
.........................................................................................................................................................................
......................................................................................................................................................................... .........................................................................................................................................................................
.........................................................................................................................................................................
Quality inspector
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Date:
.........................................................................................................................................................................
Technical informations
Ambient temperature
Degree of protection
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Form
..............................................................................................................................................................kA/sec .........................................................................................................................................................................
Top
Bottom
Other
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1. Composition
Number of cubicles Order of cubicles Project and switchboard identication markers Cubicles identication Dimensional inspection Switchboard Length Width Height Depth Fixing points.
2. Appearance
Paint colour and reference Homogeneity Finishing Front face and mimic diagram
3. Framework
Panelling / Operation of doors and mechanical accessories Inspecting key lock and number Frame mechanical assembly Handling device Check the degree of protection
5. Mechanical check
Manual operation of mechanism Operating safety (jamming safety margin) Devices accessibility Equipment xing Limit travel contacts: circuit-breaker - drawer - etc. Jaws installation Grease
6. Accessibility
Functional units or devices Access for installation, joint, junction kit, oor xing bolt Access for maintenance operations
7. Mechanical setting
Power plug-in penetrations Freedom of the power clamp ngers of contact pressure Auxiliary block installation
12. Clearances
Inspection Clearance:14 mm Creepage distances: b 14 mm for rated insulation voltage 750 V AC and DC b 16 mm for rated insulation voltage 1000 V AC and DC.
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After nal inspection and according to contract clauses, the Quality inspector may run a check of the project accompanied by a sales engineer and the client or his representative. During acceptance procedure, the client ensures that the specications have been respected. N.B.: The procedures mentioned in this guide are given as per indication. After nal inspection, the followings are required: b check that all the boxes of the checking program have been filled in b check any reworks noted on the non quality record board and sign in the relevant boxes b record and draft the final inspection report b note the final inspection report registration number on the checking program b ask the quality manager to validate the report (1) b draft and record the delivery sheet. (1) The nal inspection should be signed by the client or his representative after client acceptance inspection.
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PE50659
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Quality dashboard
8.1 Purpose
This dashboard allows the measurement of the quality performance and reveal the necessary corrective actions to implement.
8.2 Principles
The quality assurance manager issues a monthly quality report entitled Quality indicator report. Performance is evaluated according to the four indicators below: b purchased non quality b produced non quality b non service quality b external non quality.
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The non quality index: b is an indicator used to measure changes in non quality b defines the target aims b reveals the weaknesses of the various operations and allows the relevant actions to be taken. These non quality indices can be calculated using specic formulas (see chapter 9.3). The index witch is directly associated to the nal inspection is produced non quality. Purchased non quality can be monitored by different indicators depending on the supplies origin: b global ratio b ratio of the supplies purchased b internal manufactured supplies ratio. External non quality: b taking clients complaints into account (intermediate or end users).
Quality dashboard
b critical: a fault which, according to judgement and experience, is likely to result in a lack of safety or risk of accidents for the user. It presents a real danger for persons and equipment. Weighting The weighting applied to these three types of faults is: b minor fault = 1 b major fault = 3 b critical fault = 10 Produced non quality is monitored by means of indicators for each type of product and a global indicator. Remarks: Note 1: in the distribution switchboards (PCC), the number of cubicles indicated corresponds to the number of cubicles produced. Note 2: in the motor control panel (MCC), the rules are as follows: v Framework = 0.3 cubicle v < 12 m (1) drawers or functional units = 0.1 cubicle = 0.2 cubicle v u 12 m (1) drawers (1) Modules. b example of a MCC cubicle made up of: 1 framework (1 x 0.3) = 2 drawers 250 A 6 modules (2 x 0.1) = Total = Cubicle equivalent = 0.5.
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Quality dashboard
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The peaks shown on the graph may be due to: b the number of projects handled b the complexity of certain projects (complicated operating sequence) b insufficient personnel training b insufficient sensitivity of personnel b poor control of supplies b poor quality of the project production file.
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Facilities
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This area should be equipped in compliance with applicable legislation and local regulations.
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10.1 Purpose
The purpose of these operations consist in controlling the inspection and production means used in the unit for maintenance and calibration. To get a mark out of the tools on the way to perform possible correctives actions on the delivered equipment.
10.3 Responsibility
The inspection and production means responsible appointed by the quality manager is in charge of: b listing and identifying these means b implementing and monitoring the checks b decision-making after checking b archiving the documents.
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DD383187
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The calibration manager must also decide whether to initiate a notication of non conformity (NNC) used to rule on project equipment delivered which was inspected using the defective device in question as follows:
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Form example
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Quantities
Items
Quantities
Which ones? .............................................................................................................................................................................. Missing parts dispatch address: ............................................................................................................................................ .................................................................................................................................................................................................... Project site delivery date: ........................................
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Form example
Checking program
Checking program
Product : .................................................................... Final inspection registration n : ................................ Client : ....................................................................... Project n : .................................................................
Assembly : .................................................................... Quality : .................................................................... Continuous inspection Quality inspection Checked by Repair Conform Nb of faults
Cubicle identication :
Checked by Observations (1) 1 Number, identication and dimension of cubicle 2 Paint - aspect 3 Framework assembly - handling devices - keys 4 Protection index 5 Devices location and identication 6 Devices label conformity, circuit identication 7 Devices accessories 8 Current transformer characteristics and installation 9 Fault trip - mechanical pre-tripping function 10 Clamps installation and grease 11 Bus bars characteristics 12 Bars and supports installation 13 Connection conformity 14 Tightening - varnish 15 Conductors identications 16 Insulating and creepage distances 17 Cleaning 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Devices mechanical function Devices characteristics Operating and maintenance access Terminal pads conformity (cable entry and size) Devices safety perimeter Conductors characteristics and installation Monitoring of the protection circuit Electrical operating inspection Insulating test Dielectric test Form partitionning Final inspection record Customer acceptance report Missing part list Drawing as built Non quality record board Devices specication sheet Packaging Separate equipment delivery
Checking during process: full the grey box Final inspection and test: full the white box (1) N.B.: tick the box and annotate the observation on the event record sheet Full the box with NA for not applicable mention.
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Form example
Manufacturing: Quantity:
Date:
Repair action
Repaired Duration Checked by Q.I.
Design / tendering
Manufacturing
Sum of faults
Page:
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Form example
From: .................................................................................
To: .................................................................................
Detected internally
Any sugestions
Date: ..................................................
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Form example
Nom du tableau / Switchboard identication ............................ ..................................................... Produit / Product Quantit / Qty : : ................................................. ................................................. .................................................
delivery
Plan n / Drawing n :
6. Essais disolement / Insulating test Circuit / Circuit Tension dapplicat. / Applied voltage Valeur disolement / Insulation value
Observation / Comment:
................................................................................................................................................................................................... ...................................................................................................................................................................................................
.......................................................................... ..........................................................................
Date ......................................
.................................................................... ....................................................................
Date ......................................
.....................................
Visa ......................................
Visa ......................................
Visa ......................................
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Form example
1. Missing parts list / Liste des composants non expdis avec laffaire
Item / Poste
Designation / Dsignation
Quantity / Quantit
...................................................................................................................................................................................................
Quality inspector / Inspecteur qualit
...................................................................................................................................................................................................
Date ......................................
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Glossary
Abreviations
B.N.M.: National Metrology Ofce. L.V.: Low Voltage. I.E.C.: International Electro-technical Commission. Dielectrimeter: A device used only to perform dielectric tests. Dielectrometer: A device used for withstand testing. It measures dielectric withstand and insulation resistance. I.P.: Degree of Protection. Q.I.: Quality Inspection. N.N.C.: Notication of Non Conformity. I.T.P.: Inspection and Test Programme. P.E.: Electrical Protection. P.E.N.: Electrical Protection and Neutral. C.T.: Current Transformer. MCC: Motor Command and Control PCC: Power Command and Control
Vocabulary
Main denitions (Standard ISO 9000) Quality Degree to witch a set of inherent characteristics fulls requirement Quality audit Methodical examination of all the measures described in the quality manual and his relevant procedures, in co-operation with the involved parties. This on the way to evaluate whether the real statement of the plant is in harmony with the description of the quality manual. Quality management Co-ordinated activities dedicated to direct and control an organisation with regard to quality. Also include the evaluation of the results and the correspondent cost. Quality manual Written documents specifying information about the quality management system of an organisation. Quality plans Documents describing how the quality management system specify witch procedures and associated resources shall be applied by whom and when, on the way to obtain the quality level of the considered project, product, process or contract. Also called quality insurance program. Procedures Specied way to carry out an activity or process. Written document describing the organisation and manufacturing method, control, inspection, checking, assessment, corrective actions intended to be strictly applied on the way to reach the predene quality level. Inspection Conformity evaluation done in the scope of dened process by observation, measurement, testing or gauging. Non conformity Non fullment or deviation of a need or expectation with respect of the specied requirement. Traceability Ability from registered identication, to trace the history process and the location of the product after delivery.
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