ACTIVITY

SR.NO
1
2
3
4
5
6
7
8
9
10

11
12
13
14
15
16
17
18

19
20
21
22
23

24
25

OLD
oil impreganation of cylinder
near wdg cyl. Pasted
no kit preparation ( ready cyl.)
Segment marking with water tube
Lifting of kit with cotton tape
former plank with no groove
former diameter set by hand
At starting below lead no insulation
Lead anchoring done
End disc turn are stiched

AGM
not
NOT PASTED
kit ready with all insulation( btm )
Segment marking with laser beam
lifting of kit with rachet+ endless belt
former plank with groove
former diameter set by motorised tool
At starting below lead 0.65 thk craft paper arrange
No lead anchoring done
not stiched

At beginning one x'position done & all insulation

check if good no insulation done in whole winding
At every X'postion insulation done
( machine bender )
At end of wdg CTC continuity check
At starting+ end of wdg CTC continuity check
Using sectors for disc winding
Using rider tool
No solution is for epoxy softning
Spraying OKS-1111 for epoxy softning
cutting CTC at 90 deg for brazing
cutting CTC at 45 deg for brazing
lead insulation done by one crepe paper
Lead insulation is done by 2-3 crepe paper in
in hand
hand
Total insulation is done by hand
Insulation tube is inserted after few layer
"S" Bend's marking+bend done by
"S" Bend is done automatically by m/c
manually
( programme loaded by design dept.)
Strip cond. Brazing lap or but joint used
Strip cond. Brazing lap or but joint used by
without hammering conductor.
hammering conductor.
At c.o blk are same so scissoring effect
Bay length is min. 65 mm. & above

At c.o one cond height less, no scissoring effect

Bay length is min 150 mm for N-Range & 200
mm for H-Range
Shield conductor prepared during winding Shield conductor prepared outside wdg machine
Shield cond.brazed at OD
Shield is preprepared so no joint
Different activity diff person i.e: crane
operator, sweeper, helper etc.

Every workmen is complete operator,i.e; he work

on m/c, operates cranes, cleans his place , no
helper

REMARKS
moisture absorbtion minimize
CYL. Shrinkage after VPD/OVEN deform
Lead time of wdg reduce
safe and quick
helps to fix bottom base for the winding
lead time reduce
conductor protection
better protection
Better mechanical support

lead time reduce

At start only we reduce risk
Rider is one time cost
Epoxy lead even after ovening is soft to handle
Joint at 45 deg is best.
Better overlapping with min. thickness.
Lead time reduce / ( slightly loose )
Accurate and reduced lead time
Sharp edges increases electrical stress,even
through the conductor is smoothen,slighty edges
are there.
No scissoring effect at c.o
More length for "S" bend working easy no
scissoring , hence no insulation required at c.o
Lead time reduced
No loosening in condutor

All round performance , reduce lead time.

BAD
GOOD

SR.NO

ACTIVITY

TELK

T&R

YES
YES
YES
WITH PLUMB
with canvas belt
NO
manual + motorised
YES
YES
YES
YES

Only Heating
YES
NO
water tube
NA
NO
manual
NO
YES
YES
YES

YES
YES

YES
NO

YES ( 4-PIECE)
NO
450 at width.

NA
NO
900 at thick.

original kraft+2-layer crepe

original crepe

1
2
3
4
5
6
7
8
9
10
11

Oil impregnation of Cylinder

near wdg cyl. Pasted
kit preparation ( ready cyl.)
Segment marking
Lifting of kit (cyl)
former plank with groove
former diameter setting
At starting below lead insulation
Lead anchoring done
End disc turn are stiched
Insulation at every X'postion

12
13

14
15
16

At end of wdg CTC continuity check

Before starting of wdg CTC continuity
check
Using sectors for disc winding on
vertical m/c
Epoxy softning treatment
CTC cond. Cutting for brazing

17

Lead bend insulation

18
19

Lead insulation
" S" -bend marking

All manually
Manually

All manually
Manually

20
21
22
23

"S" bending
Strip conductor brazing
CTC cond. brazing
Bunch(strip) cond brazing
Cond hammering for preparation of
Bunch cond.brazing

Manually/jig
Butt+lap
Butt
Lap

Manually/jig
Butt
NA
Butt

24
25
26
27
28
29
30

NO
Radially one cond./ turn
At Cross-over position blk dimention minus
Bay length for cross-over
Two segment
Bay length for cross-over
Min 150 mm
Shield conductor preparation.
Before winding(both end )
Shield joint
NO
Shield position
ID + OD

31

Shield direction

NO
winding blk
one segment

During winding
YES
OD
counter
Winding + counter winding
winding

CGL

SIEMENSABB

Heating+Vacuum+oil dipping
YES
NO
water tube
NA
NO
manual + motorised
NO
YES
YES
YES

YES
NO
spirit level
NA

YES

AREVA,Naini
NO
YES
NO
with water tube+ plumb+sprit level
NA
NO
manual + motorised
partially YES
YES
YES
YES

YES
NO

YES
NO

YES ( 4-PIECE)
NO( MEK, but not good result)
900 at thick.
Original insulation on LV by
nomex & For other crepe

YES ( 4-PIECE)
NO
NA
Original insulation by crepe

All manually
Manually

All manually
Manually

Hydraulic bender
Lap
Lap
Lap

Jig/ Hydraulic bender

Butt
NA
Butt

NO

NO

winding blk
one segment
Min 70 mm
During winding
YES
OD

winding blk
one segment
Min 70 mm
During winding
YES
OD

counter winding

counter winding

AREVA , AGM

Good Practice

PURPOSE

Heating only
NO
YES
laser beam +spirit level
Endless slings
YES
motorised
YES
NO
YES
NO( Depending on
insulation after bend
NO
YES

Oil impregnation should be done

near wdg cyl should not be pasted
kit preparation should be done
segment marking by laser beam
lifting of kit with ratchet belt
former plank with groove is best
motorised is good for diameter setting
at starting insulation below lead
lead anchoring must be done
end turns should be stiched
insulation must be done

moisture absorbtion minimize

CYL. Shrinkage after VPD/OVEN deform
to reduce winding lead time
perfect alignment of strips (uniformity)
easy
used for base tightening & lead arranging
reduce lead time & labour
additional protection to lead
to resist spring back effect of conductor
it gives good holding to last turn
to have better elec & mech strength

it must be check
it must be check

to check any abnormality during winding

to check any abnormality before winding

YES ( standard , special)

OKS-1111
450 at thick.
Original kraft+ one layer
crepe
Few layer manully +
insulation tube
Automatic by machine

Rideover clip(standard size)

OKS spraying must be done
450 cutting is good

only one time making & cost saving

for easy handling of Epoxy cond after oven
more area for butt joint+avoids over-build
Kraft peper gives good elec & crepe
paper good mech strength

Original kraft+ one layer crepe

single paper insulation is to be done
marking by machine is good
Jig/machine (elec)+hydrolic bender both
good
lap brazing
butt brazing is good
butt brazing is good

Jig / machine( elect)

Butt+lap
Butt
Butt
YES(for reducing
thcikness)
hammering is not good
Radially one cond./ turn
minus
Radially one cond./ turn minus
Two segment
Two segment
Min 150 mm
Min 150 mm
Before winding(one end )
separate shield cond preparation
NO
no
ID + OD
design issue
Winding + counter
winding
design issue

for better elec & Mech strength

high accuracy & lead time saving
good
more area for brazing
avoids over-building
more area for brazing
hammering reduces cond strength
it avoids scissoring effect
it reduces sharp edge
more space for crossover
saves winding lead time
joint should be avoided
design issue
design issue

nd after oven

LTI , VADODARA

Sr
Core Cutting Shop

ACTIVITY

TELK

INSULATION

T&R

CGL

SIEMENS

ABB

AREVA,Naini

??
Not always

the machine

32

House keeping

Individual
dept.
Not by

Individual dept.

Manual house keeping

33

work area cleaning

operator

Not by operator

34

Edge rounding activity

35

Strip cutting

M/C
upto 3 mm by M/C
shearing
m/c upto 3 mm by shearing m/c
Semi-

Not by
with
theoperator
help
of knifemachine
and sand
Cutting
on
shearing
and
paper
after cutting finishing is done

36

Pressboard cutting

automatic

37

Thickness finishing of helical end coller

out sourcing

38

Sign and stamp on check list

out sourcing
Sign
on check out sourcing
list
NO

39

Pressboard sheet handling

Manually

Special jig(operate by crane)

Manually

40

Safety(eye_protection)

NA

NA

41

Pressboard cylinder handling trolley

NA
Hydraulic
trolly

Trolly

Trolly

42

Cylinder handling

43

Safety(eye and ear)

Not always

Not always

manually

Semi-automatic

AREVA , AGM
Portable dust collection
Edge
rounding
by
machine
and centralised
company
Name
duct collector
system
for
Wegoma,Model-KFR
every machine,Self
30,Weight-1.7
Kg,Chuck
discipline operator is
collet
- 8mm,No-load
responsible
for own
speedmachine
cleanliness
done
by automatic
strip
30000/min,Acoustic
By
portable
PCompany
cutting
machine , 6
By OPERATOR
pressure
level
- 81.4
Name
- Dewalt,Modelnoumber
of strip
can be
bB(A)
D26500(K)/D26501K,Pla
cut within 4-5 min with
ning
depth
- 25
proper
finishing.
by automatic
pressboard
AGM
has develop
a82
mm,Planing
widthEye wash
bottel
cutting
maching
special
design
trolley
mm,Base
length
- 320, is
BARIKOS
, This
bottle
easy
handling
,
less
mm
used as a first aid time
taken andtosafe
and
measure
rinse
the eye
AREVA , of
AGM
capacity
this trolley is
in order to remove
10-13have
sheetdevelop
at one time.
They
a
penetreted
substances
secial
trolley
for
(dust and
chemical)
pressboard
cylinder
Every work man wearing
handling,and
it is safety
easy safe
ear-plug
and
lesswhile
timeworking
taken on
goggle

semi-automatic
Sign on check list

Good Practice

PURPOSE

AREVA,AGM
AREVA,AGM(only
one itperson
AREVA,AGM because
is timerequired
saving
and
this
machine
cut 1mm
to 30mm
and
quality
of workcan
is much
better
AREVA,AGM(only
one
person
required
thick
pressboard sheet,raw
material
for
and
is very
good
everyfinishing
machines
are cut
by) this machine
only
AREVA,AGM(portable,time saving and
finishing is good)

AREVA,AGM
AREVA,AGM
AREVA,AGM

WINDING
1
2
3
4
5
6
7
8
9
10
11

Oil impregnation of Cylinder

near wdg cyl. Pasted
kit preparation ( ready cyl.)
Segment marking
Lifting of kit (cyl)
former plank with groove
former diameter setting
At starting below lead insulation
Lead anchoring done
End disc turn are stiched
Insulation at every X'postion

YES
YES
YES
WITH PLUMB
with canvas belt
NO
manual + motorised
YES
YES
YES
YES

Only Heating
YES
NO
water tube
NA
NO
manual
NO
YES
YES
YES

Heating+Vacuum+oil dipping
YES
NO
water tube
NA
NO
manual + motorised
NO
YES
YES
YES

YES
YES

YES
NO

YES
NO

YES ( 4-PIECE)
NO
450 at width.

NA
NO
900 at thick.

12
13

14
15
16

At end of wdg CTC continuity check

Before starting of wdg CTC continuity
check
Using sectors for disc winding on
vertical m/c
Epoxy softning treatment
CTC cond. Cutting for brazing

17

Lead bend insulation

18
19

Lead insulation
" S" -bend marking

All manually
Manually

All manually
Manually

All manually
Manually

All manually
Manually

20
21
22
23

Manually/jig
Butt+lap
Butt
Lap

Manually/jig
Butt
NA
Butt

Hydraulic bender
Lap
Lap
Lap

Jig/ Hydraulic bender

Butt
NA
Butt

24

"S" bending
Strip conductor brazing
CTC cond. brazing
Bunch(strip) cond brazing
Cond hammering for preparation of
Bunch cond.brazing

25
26
27
28
29
30

At Cross-over position blk dimention

Bay length for cross-over
Bay length for cross-over
Shield conductor preparation.
Shield joint
Shield position

31

Shield direction

original kraft+2-layer crepe

NO
Radially one cond./ turn
minus
Two segment
Min 150 mm
Before winding(both end )
NO
ID + OD

YES ( 4-PIECE)
NO( MEK, but not good result)
900 at thick.
Original insulation on LV by
original crepe
nomex & For other crepe

YES
NO
spirit level
NA

YES

NO
YES
NO
with water tube+ plumb+sprit level
NA
NO
manual + motorised
partially YES
YES
YES
YES
YES
NO

YES ( 4-PIECE)
NO
NA
Original insulation by crepe

NO

NO

NO

winding blk
one segment

winding blk
one segment
Min 70 mm
During winding
YES
OD

winding blk
one segment
Min 70 mm
During winding
YES
OD

counter winding

counter winding

During winding
YES
OD
counter
Winding + counter winding
winding

Heating only
NO
YES
laser beam +spirit level
Endless slings
YES
motorised
YES
NO
YES
NO( Depending on
insulation after bend
NO
YES

Oil impregnation should be done

near wdg cyl should not be pasted
kit preparation should be done
segment marking by laser beam
lifting of kit with ratchet belt
former plank with groove is best
motorised is good for diameter setting
at starting insulation below lead
lead anchoring must be done
end turns should be stiched
insulation must be done

moisture absorbtion minimize

CYL. Shrinkage after VPD/OVEN deform
to reduce winding lead time
perfect alignment of strips (uniformity)
easy
used for base tightening & lead arranging
reduce lead time & labour
additional protection to lead
to resist spring back effect of conductor
it gives good holding to last turn
to have better elec & mech strength

it must be check
it must be check

to check any abnormality during winding

to check any abnormality before winding

YES ( standard , special)

OKS-1111
450 at thick.
Original kraft+ one layer
crepe
Few layer manully +
insulation tube
Automatic by machine

Rideover clip(standard size)

OKS spraying must be done
450 cutting is good

only one time making & cost saving

for easy handling of Epoxy cond after oven
more area for butt joint+avoids over-build
Kraft peper gives good elec & crepe
paper good mech strength

Original kraft+ one layer crepe

single paper insulation is to be done
marking by machine is good
Jig/machine (elec)+hydrolic bender both
good
lap brazing
butt brazing is good
butt brazing is good

Jig / machine( elect)

Butt+lap
Butt
Butt
YES(for reducing
thcikness)
hammering is not good
Radially one cond./ turn
minus
Radially one cond./ turn minus
Two segment
Two segment
Min 150 mm
Min 150 mm
Before winding(one end )
separate shield cond preparation
NO
no
ID + OD
design issue
Winding + counter
winding
design issue

for better elec & Mech strength

high accuracy & lead time saving
good
more area for brazing
avoids over-building
more area for brazing
hammering reduces cond strength
it avoids scissoring effect
it reduces sharp edge
more space for crossover
saves winding lead time
joint should be avoided
design issue
design issue

32

House keeping

33

work area cleaning

34

35

36

Edge rounding activity

Strip cutting

Pressboard cutting

37

Thickness finishing of helical end coller

38

Sign and stamp on check list

39

Pressboard sheet handling

40

Safety(eye_protection)

41

Pressboard cylinder handling trolley

42

43

Individual
dept.
Not by
operator

M/C

Individual dept.

Manual house keeping

Portable dust collection

machine and centralised
duct collector system for
every machine,Self
discipline operator is
responsible for own
machine cleanliness
AREVA,AGM

Not by operator

Not by operator

By OPERATOR

with the help of knife and sand

paper

Edge rounding by
company Name Wegoma,Model-KFR
30,Weight-1.7 Kg,Chuck
collet - 8mm,No-load
speed30000/min,Acoustic
pressure level - 81.4
AREVA,AGM because it is time saving
bB(A)
and quality of work is much better

Cutting on shearing machine and

after cutting finishing is done
manually

done by automatic strip

cutting machine , 6
noumber of strip can be
cut within 4-5 min with
proper finishing.

semi-automatic

AREVA,AGM(only one person required

and this machine can cut 1mm to 30mm
thick pressboard sheet,raw material for
by automatic pressboard every machines are cut by this machine
cutting maching
only

out sourcing

By portable PCompany
Name - Dewalt,ModelD26500(K)/D26501K,Pla
ning depth - 25
mm,Planing width- 82
mm,Base length - 320
AREVA,AGM(portable,time saving and
mm
finishing is good)

Sign on check list

AREVA , AGM

Manually

AGM has develop a

special design trolley ,
easy handling , less time
taken and safe and
capacity of this trolley is
10-13 sheet at one time.

NA

NA

Eye wash bottel

BARIKOS , This bottle is
used as a first aid
measure to rinse the eye
in order to remove
penetreted substances
(dust and chemical)
AREVA,AGM

Trolly

Trolly

M/C

upto 3 mm by
shearing m/c upto 3 mm by shearing m/c

Semiautomatic

Semi-automatic

out sourcing out sourcing

Sign on check
list
NO

Manually

NA
Hydraulic
trolly

Special jig(operate by crane)

Cylinder handling

Safety(eye and ear)

Not always

Not always

AREVA,AGM(only one person required

and finishing is very good )

??

They have develop a

secial trolley for
pressboard cylinder
handling, it is easy safe
and less time taken

Not always

Every work man wearing

ear-plug and safety
goggle while working on
the machine
AREVA,AGM

AREVA,AGM