Job Title
: Core & CCA Engineer
Department
:
Production / Manufacturing
Location
:
Atlas Transformers India Limited (Por,GIDC)
Reports To
:
Production Manager / Plant Head / Manufacturing Supervisor
Industry
:
Transformer Manufacturing – Power & Distribution
Job Summary
The Core & CCA (Core Coil Assembly) Engineer is responsible for overseeing the core assembly and coil integration process, a critical stage in transformer manufacturing. This role involves the precise stacking of the magnetic core, careful handling and placement of LV and HV coils, and assembling the core-coil unit to exact design tolerances. The Core & CCA Engineer ensures the assembled unit meets mechanical, electrical, and thermal design parameters and is ready for tanking and further processing. The engineer works closely with design, winding, tanking, insulation, and quality teams to maintain production efficiency, safety, and product reliability.
Key Responsibilities
- Core Assembly:
- Supervise the stacking and assembly of transformer cores (CRGO/Amorphous) according to technical drawings and specifications.
- Ensure correct core limb formation, yoke assembly, and accurate dimensioning (height, width, depth, window height).
- Check and control the core stacking factor, lamination orientation, and core loss optimization.
- Coil Mounting and Assembly:
- Oversee the positioning of LV and HV coils on the core limbs with proper alignment and phasing.
- Ensure correct use of insulation materials, spacers, and clamping systems during CCA to maintain dielectric and mechanical integrity.
- Verify concentricity, axial clamping, and radial support to minimize vibration and short-circuit stress.
- CCA Finalization and Clamping:
- Assemble and fix the complete core and coil unit using clamping frames, tie rods, and pressure rings.
- Ensure correct positioning of tap leads, neutral leads, and terminal connections as per design.
- Prepare the CCA for drying, tanking, and oil-filling by confirming structural and dimensional conformity.
- Process Control and Quality Assurance:
- Conduct in-process checks to ensure adherence to engineering drawings and quality standards.
- Inspect and document assembly parameters such as coil-to-core clearance, inter-coil distances, limb centering, insulation placement, and torquing of fasteners.
- Resolve quality issues like coil deformation, insulation misplacement, lead misalignment, or core damage.
- Team Supervision and Training:
- Supervise technicians and fitters in core stacking and CCA operations.
- Train assembly teams in proper handling techniques of cores and coils to prevent mechanical damage and contamination.
- Promote safety, discipline, and 5S principles on the shop floor.
- Coordination with Departments:
- Liaise with the design team to clarify technical drawings and special assembly requirements.
- Coordinate with winding, insulation, and tanking departments for timely input/output of materials.
- Support the testing and quality departments in type tests and FAT (Factory Acceptance Test) by providing correct assemblies.
- Documentation and Reporting:
- Maintain records of assembly activities, including coil serial numbers, insulation material traceability, torque settings, and dimensional reports.
- Prepare daily/weekly reports on assembly progress, issues, and manpower utilization.
- Contribute to root cause analysis for non-conformities and support continual improvement initiatives.
Required Qualifications
- Education: Diploma / B.E. / B.Tech in Electrical, Mechanical, or Production Engineering
- Experience: 3–8 years of experience in transformer core assembly and CCA, preferably in power or distribution transformer manufacturing
- Technical Skills:
- In-depth knowledge of transformer construction, core materials (CRGO), and insulation systems
- Ability to interpret mechanical drawings, core assembly schematics, and winding layouts
- Familiarity with measurement tools (Vernier, micrometers, height gauges) and lifting equipment
- Understanding of clamping torque, lead routing, mechanical tolerances, and dielectric clearances
Key Competencies
- Attention to precision and structural accuracy
- Strong coordination and communication skills
- Problem-solving and decision-making abilities
- Mechanical aptitude and safety awareness
- Team leadership and training capability
- Ability to work under pressure and meet production deadlines
Working Conditions
- Shop floor-based role, involving standing, lifting, and mechanical work
- Use of PPE (Personal Protective Equipment) required
- May involve rotational shifts, overtime, or working on holidays during critical delivery periods
- Exposure to magnetized materials, oils, and large electrical components
Additional Desirable Qualifications
- Experience with large power transformers (132kV to 765kV) is an advantage
- Basic understanding of ISO 9001, 14001, 45001 compliance
- Familiarity with ERP systems (SAP, Oracle) for production tracking
- Knowledge of 5S, Kaizen, or Lean Manufacturing principles
Skills: dielectric clearances,insulation systems,lifting equipment,transformer construction,clamping torque,winding layouts,mechanical tolerances,assembly,core materials (crgo),measurement tools (vernier, micrometers, height gauges),lead routing,coil,transformer,mechanical drawings interpretation,core assembly schematics
