Gamesa energy Transmission covers casting, machining, heat treatment and assembling capacities.
Gamesa Energy Transmission (GET) is a gearbox manufacturer inside Siemens Gamesa Renewable Energy (SGRE), a market leader in the wind energy industry. Mario Roy Flores works for SGRE since 2006 in different positions related to Gearbox manufacturing as Process implementation engineer, product owner, product integration in nacelle and, lately, as Gearbox quality manager.
How did you learn about the project? What aspects of the project attracted you to join it?
I learned about the project through the digitalization focal point of the Gearbox Engineering department. I was interested in the potential quality improvement through the process optimization.
How is work carried out at your production plants on a daily basis?
Gamesa energy Transmission covers casting, machining, heat treatment and assembling capacities. InterQ project is focused in two critical stages: machining of the different components in the facilities located at Asteasu (Basque Country, Spain) and assembly operations performed at Lerma (Burgos, Spain). Flexible production means are used in all the manufacturing stages. This flexibility is a necessity, as wind industry projects execution requires that gearboxes are produced in small and medium size batches.
Why is Zero-Defect Manufacturing so important for your company?
The Non-Conformity Cost is the main KPI owned by the quality department at GET. This indicator represents the incremental costs incurred when it fails to meet the quality requirements for its products. The big unit-cost of the gearboxes makes any faulty component impacting the company benefits. The biggest part of the non-Conformity Cost in the Gearbox unit is driven my manufacturing costs.
Which are the main problems faced currently?
The main quality problems faced by GET are related to raw material quality (castings and forgings), gear grinding and machining process deviations due to manual parameter adjustment done by operators. This is why GET is addressing the automation of ultrasonic testing (for forgings non-destructive-testing), the monitoring of vertical grinding process and improvement based on process data, the vertical lathe process improvement based on measurement data and, at the end of the process, the gearbox testing data analytics.
How do you expect InterQ will improve your production?
GET expects to improve process control and product quality thanks to InterQ project, resulting in a reduction of the Non Conformity Report(NCR) amount in the processes.