I- Introduction

II- Power transformers

III- Case Study

IV- Conclusion

References

Abstract

Industry is undergoing through noteworthy changes, where most of the methodologies and procedures are increasingly assisted by advanced information systems. In addition, the communications between the entire product chain have been progressively more effective, allowing to support better decisions in the early phases of the product development. This industrial change demands companies to rethink the planning, design and manufacturing phases, so as to take advantage of these developments. This article addresses an empirical assessment based on the Design for eXcellence (DfX) concepts aiming a smarter design and manufacturing of fully customized power transformers. Several design for excellence disciplines are discussed and analysed considering a specific case study, where the transformer tank geometry was changed. The resulting consequences in the final product can be systematized analysing the overall product lifecycle. Inputs to the product development through these design disciplines have the capability to identify advantages, disadvantages and improvement opportunities. Furthermore, the accumulated knowledge and the consideration of these approaches in a continuous improvement action will allow the enhancement of the efficiency and reliability throughout the design and production cycle of a power transformer. Index Terms—Power Transformers, Design for X, Design for Excellence, Product Development, Product Life Cycle

INTRODUCTION

In customized, large-scale and complex products, the conceptualization, budgeting and design phases of the product lifecycle management represent a significant effort, cost and risk due to the presumed assumptions, requirements balances and available lead time. These phases limit the ability to provide a faster and more accurate response to the demands of a customer. Therefore, organizational and functional solutions that streamline the entire design and production cycle are extremely valuable in this type of products. In order to follow the market trends and increase competitiveness, several projects have begun to reorganize the methodologies in practice. The aim is to find the best trade-off between cost-quality-time, regarding the planning, design and manufacturing phases. The product development of complex systems includes many different interactions between diverse stakeholders. Most approaches for product development systematization might be reduced to a four stage-gate framework: (i) concept development; (ii) design; (iii) validation and (iv) in-service product support, [1]. As the product complexity increases more phases and/or stages are added for a more rigorous control. Typically, a more detailed second stage framework, related to the design (and development), will reduce the effort required in the third stage and the respective risks. Diverse tools and methodologies for product development have been developed in multiple contexts. For instance, Lutters et al., in [2], details the common techniques for structuring the product development process and improve the decision making.