TF Core Lamination Cutting/Building Manager - Transformer

Job Description:

Designation: TF Core Lamination Cutting/Building Manager
Department: Core Shop - Transformer Manufacturing
Reporting To: Head - Manufacturing / Plant Head
Location: Chittoor, Andhra Pradesh
Transformer Capacity Range: Up to 20 MVA (Power & Distribution Transformers)
Qualification: B.Tech (Electrical / Mechanical / Metallurgical Engineering)
Experience: 15 Years (Transformer / Heavy Electrical Equipment Manufacturing)

JOB PURPOSE
Own the end-to-end core lamination cutting and core building process for power and distribution transformers, ensuring that CRGO lamination quality, core loss performance, and stacking accuracy consistently meet design and customer specifications. Responsible for planning, manpower deployment, machine utilization, and continuous improvement of the core shop to support the plant's production plan while minimizing CRGO wastage and core-related non-conformances.

PROJECT PHASE RESPONSIBILITIES
- Review core design drawings (step-lap / mitred joints, limb & yoke dimensions, stacking pattern) with the design/R&D team for new transformer orders and flag manufacturability concerns early.
- Plan CRGO grade and gauge requirements against the order book and coordinate with Purchase/SCM for timely material availability.
- Set up tooling, dies, and cutting-line programs (slitting, cut-to-length, notching) for new core geometries and transformer ratings.
- Conduct first-article core builds and coordinate core-loss and stacking-factor verification before releasing a new design to regular production.
- Support prototype and type-test units with special attention to core assembly accuracy and no-load loss targets.
- Provide core-shop capacity and lead-time inputs during project planning and order scheduling reviews.

PRODUCTION PHASE RESPONSIBILITIES
- Prepare and monitor daily/weekly core cutting and building schedules aligned with the winding and assembly sections' pull requirements.
- Supervise operation of slitting lines, cut-to-length lines, and shearing/notching equipment to ensure dimensional accuracy and burr-free edges.
- Oversee core stacking/building operations, ensuring correct step-lap overlap, clamping pressure, and insulation coating integrity.
- Monitor and control CRGO scrap/wastage against budgeted norms; drive nesting optimization to improve material yield.
- Coordinate core-loss (no-load loss) testing of built cores and address deviations through root-cause analysis.
- Maintain FIFO/traceability of CRGO coils and laminations by grade, gauge, and heat/batch number.
- Ensure timely handover of built cores to the winding/assembly section as per production schedule.
- Drive 5S, machine uptime, and preventive maintenance coordination with the Mechanical/Electrical maintenance teams for cutting-line equipment.

TECHNICAL SKILLS
- In-depth knowledge of CRGO steel grades, magnetic properties, and core-loss behaviour.
- Expertise in step-lap/mitred core construction, stacking-factor optimization, and core geometry calculations.
- Hands-on experience with slitting lines, cut-to-length lines, and automatic/semi-automatic core stacking machines.
- Working knowledge of core design software / AutoCAD and nesting optimization tools.
- Understanding of no-load loss and excitation current testing and its correlation to core-building quality.
- Familiarity with IS 3024 (CRGO specification) and relevant transformer core design standards.

LEADERSHIP REQUIREMENTS
- Lead a team of 30-50 core shop supervisors, machine operators, and helpers across shifts.
- Coordinate closely with Design/R&D, Winding, Core-Coil Assembly, Purchase/SCM, and Quality functions.
- Drive skill development and cross-training of shop-floor staff on new core designs and cutting-line technologies.
- Own shift-wise production reviews, escalate constraints proactively, and drive corrective actions to closure.
- Champion a continuous improvement (Kaizen/TPM) culture within the core shop.

KEY PERFORMANCE INDICATORS (KPIs)
- Core loss (no-load loss) deviation from design target (%).
- CRGO scrap/wastage % against budgeted norm.
- Stacking factor / core-building first-pass yield (%).
- On-time delivery of built cores to the winding/assembly section (%).
- Core-shop machine uptime and OEE.
- Safety incident/near-miss rate in the core shop.

SAFETY & COMPLIANCE RESPONSIBILITIES
- Ensure strict compliance with machine guarding norms on slitting, shearing, and cutting equipment.
- Mandate use of cut-resistant gloves, safety footwear, and eye protection while handling CRGO laminations.
- Enforce Lock-Out-Tag-Out (LOTO) procedures during maintenance of cutting-line machinery.
- Maintain safe stacking, storage, and handling practices for CRGO coils and cut laminations to prevent edge-injury and material damage.
- Ensure adherence to ISO 9001 / ISO 14001 / ISO 45001 and plant EHS protocols, including housekeeping (5S) standards.
- Conduct periodic safety audits and toolbox talks specific to core-shop hazards (sharp edges, material handling, crane movement).