Discrete / assembly
ERP for Transformer Manufacturers
Every unit is serialised, every test report follows that serial for years, and CRGO offcuts are too valuable to write off. This is discrete manufacturing with a paperwork problem.
- Stages mapped
- 8
- Quality checks
- 4
- Wastage rules
- 3
- Compliance items
- 3
Your process
The stages, already mapped.
Core building to testing with serialised traceability. These are the stages the template ships with — machines and checks included. Yours will differ in detail; that is configuration, not development.
- 1
Core cutting
Cut CRGO laminations to design with burr control
- Machines
- CRGO cutting line
- Checked
- Dimension, burr < 20 µm
- 2
Core assembly
Stack and clamp laminations to designed core
- Machines
- Assembly bay
- Checked
- Core loss test
- 3
Winding
LV/HV coil winding to turns and insulation spec
- Machines
- Winding machines W1–W4
- Checked
- Turns count, IR value
- 4
Core-coil assembly
Marry core and coils with clamping and lead dressing
- Machines
- Assembly bay
- Checked
- Clearances, ratio pre-check
- 5
Tanking
Place active part in tank, fit bushings and accessories
- Machines
- Crane + tanking bay
- Checked
- Fitment checklist
- 6
Oil filling
Vacuum oil filling and impregnation
- Machines
- Vacuum plant
- Checked
- BDV of oil, vacuum log
- 7
Testing
Routine tests per IS 2026 with test certificates
- Machines
- HV test lab
- Checked
- Ratio, HV, load/no-load loss
- 8
Dispatch prep
Painting, rating plate, packing and serial tagging
- Machines
- Paint booth
- Checked
- DFT check, final inspection
What goes in
CRGO, copper, insulation, oil
What comes out
Distribution transformers (serialised)
Distribution transformers 25–2500 kVA · Repair & refurbishment jobs
Who is it for
Not all transformer manufacturers work the same way.
The template is the same; what it has to answer for is not. Find the one that sounds like you — if none of them do, say so on the call and we will tell you honestly whether this is the right fit.
Distribution transformer makers
Serialised units, routine tests and warranty history.
Power & furnace transformer makers
Engineer-to-order builds against a customer drawing.
Repair & rewinding workshops
Inward units, scope on inspection, and job-wise costing.
MANUPRIME AI
Ask it about this floor, in your own words.
The AI reads the same records this template creates — so on a transformer manufacturer floor the questions it can actually answer are the ones you already ask at the morning meeting.
Questions it answers here
- “Why has first-pass test yield moved this week?” — currently 96% in the demo data
- “Why has avg build cycle moved this week?” — currently 9 days in the demo data
- “Why has copper variance moved this week?” — currently ±1.8% in the demo data
- “Where is my wastage going?” — crgo offcuts, copper scrap, costed back to the batch that caused it
- “What am I short of in the next 14 days?” — with the covering purchase order drafted for approval
And what it is not allowed to do
It shows its working, or it does not answer
It drafts. A person releases
It sees only what the person asking can see
Quality
What quality control looks like here.
Checks that hold a dispatch, at the frequency this trade actually inspects.
| Parameter | Method | Frequency |
|---|---|---|
| Turns ratio | Ratio meter | Every unit |
| HV withstand | HV tester per IS 2026 | Every unit |
| Winding resistance | Micro-ohm meter | Every unit |
| Oil BDV | BDV kit | Every filling |
Wastage and recovery
The part generic ERPs get wrong.
Most systems can only write material off. In this trade that is the difference between a costing you believe and one you argue with.
Rules that ship with this template
- CRGO offcuts weighed and sold as scrap (TCS)
- Copper scrap segregated by gauge
- Failed coils rewound — labour booked to rework
What drives your cost per unit
- Copper & CRGO weight per design (major cost)
- Serialised unit costing with test-lab hours
- Warranty provision per kVA class
In short:CRGO offcuts, copper scrap.
Compliance
What this trade has to prove.
Configured, not bolted on afterwards — the records come out of the same transactions your floor is already entering.
On the dashboard
The numbers this plant is judged on.
Sample figures from the demo, so you can see the shape of what you would be looking at every morning.
- First-pass test yield
- 96%
- Avg build cycle
- 9 days
- Copper variance
- ±1.8%
Illustrative values from the demo dataset, not a customer's figures.
Questions
Questions we get asked first.
Does each transformer carry its own test report?
Yes. Ratio, HV and temperature-rise results are recorded against the serial number, and the routine test certificate prints from those readings. Ten years later the serial still resolves to its test record.
How is CRGO scrap handled?
Core cutting yields offcuts by grade, received back into stock at a recovery rate. Lamination utilisation shows as a stage-level number, which is usually the first place a plant finds real money.
Can we cost a unit against the customer order it was built for?
Yes. Copper, CRGO, oil, insulation and labour cost to the work order, and the work order is linked to the sales order — so the margin on a specific transformer is visible, not averaged across the month.
See it running with Transformer Manufacturing data.
The demo opens with this trade's materials, machines, checks and reports already in place. No signup, nothing to install.