Transforming Transformer Manufacturing with Digital Integration
Manufacturing
AI & Data Engineering
Testing Optimization
The Opportunity
The Transformer Industry at an Inflection Point
Between 2023 and 2030, the global power transformer market is projected to grow from $25.6 billion to $49.3 billion, driven by aging grid infrastructure and renewable energy integration. However, supply chain disruptions have extended lead times for large power transformers to 36 months, while DOE efficiency standards demand advanced testing protocols to save utilities $824 million annually.
Prolec GE Waukesha recognized that their Shreveport facility expansion was being constrained by these very challenges, with on-time delivery stuck at 82% due to certification lags
The Vision
Integrated Digital Operations for Manufacturing Excellence
Prolec GE Waukesha's leadership envisioned a future where testing, certification, and production processes would be seamlessly integrated through digital transformation. Rather than fighting testing bottlenecks with traditional approaches, they sought to eliminate them entirely through intelligent automation and data integration.
Their vision was comprehensive: create a unified digital platform that would transform testing workflows from manual, error-prone processes into automated, compliance-ready operations that could scale with growing demand.
Their vision was comprehensive: create a unified digital platform that would transform testing workflows from manual, error-prone processes into automated, compliance-ready operations that could scale with growing demand.
Vision Pillars
Automated Test Data
Integration
Integration
Direct capture and processing of data from Doble, Impulse, and legacy test equipment without manual intervention.
Template-Driven
Certification
Certification
Standardized yet customizable Certified Test Report (CTR) generation tailored for each customer and transformer type.
Real-Time Production
Intelligence
Intelligence
Unified data management in TDMS with automated calculations for Heat Run, DGA, and impulse tests.
Offline-Capable
Operations
Operations
Resilient test floor operations that function independently of network connectivity while maintaining data integrity.
Compliance by
Design
Design
Built-in IEEE standards validation and automated compliance checking throughout the testing process.
Production
Optimization
Optimization
Automated incident reporting, integrated spares management, and real-time temperature (RTD) monitoring.
The Solution
Building Integrated Digital Operations with Torsion
To realize their digital transformation vision, Prolec GE Waukesha partnered with Torsion—selecting them as the strategic implementation partner to translate requirements into scalable, production-ready solutions. Torsion brought deep transformer industry expertise and understanding of the unique operational complexities in transformer manufacturing, enabling them to design solutions that integrated seamlessly with existing manufacturing workflows and legacy systems.
Technical Implementation
Core Solution
Components
Test Data Integration Platform: Direct integration with Doble M4100/M5400, Impulse analyzers, and legacy test equipment through REST APIs, database adapters, and file-based integration capabilities.
Why: To eliminate manual data transfer processes that were causing errors, rework, and certification delays.
Agent-Based Offline
Architecture
Resilient test floor application functioning independently of network connectivity with local database and automatic synchronization capabilities.
Why: To ensure continuous operations in harsh test floor environments where network reliability is inconsistent.
Template-Driven CTR
Framework
Automated Certified Test Report generation with customizable templates for power, distribution, and specialty transformers, including digital signature workflows and full audit trails.
Why: To standardize reporting processes while maintaining flexibility for different transformer types and customer-specific requirements.
Automated Calculation
Engine
Integrated calculations for Heat Run, DGA, and impulse tests with formula management and automated validation against IEEE C57.12.90 standards.
Why: To eliminate manual calculation errors and accelerate the certification process while ensuring compliance.
Centralized TDMS
Integration
Multi-site database capabilities with real-time production status dashboards, quality metrics tracking, and trend analysis.
Why: To provide unified data management across manufacturing locations and enable real-time production intelligence.
Production Optimization
Suite
To improve operational efficiency and reduce downtime through proactive maintenance and resource management.
Why: To provide unified data management across manufacturing locations and enable real-time production intelligence.
Technical Implementation Approach
The Impact
By The Numbers
Metric
Before Integration
After Integration
On-Time
Delivery
Delivery
82%
ETL Processing
Time
94%
ETL Processing
Time
Capacity
(Shreveport Facility)
(Shreveport Facility)
Baseline
Member Support
Availability
+15%
Member Support
Availability
Manual Reporting
Effort
Effort
100% (manual)
Report
Generation
Generation
70–90% reduction
Report
Generation
Generation
IEEE Compliance
Validation
Validation
Manual, time-consuming
Report
Generation
Generation
Automated, streamlined
Report
Generation
Generation
Certified Test Report
(CTR)
(CTR)
Manual, error-prone
Report
Generation
Generation
Automated, template-driven
Report
Generation
Generation
Data
Integration
Integration
Siloed/manual
Care Gap
Analysis
Analysis
Unified, real-time (TDMS)
Care Gap
Analysis
Analysis
Delivering Measurable Manufacturing Excellence
The integrated digital platform rapidly demonstrated significant operational improvements across multiple dimensions:
Enhanced Delivery Performance
On-time delivery jumped from 82% to 94%, directly addressing customer expectations and competitive pressures.
Capacity Expansion
Enabled 15% capacity expansion at the Shreveport facility by eliminating testing bottlenecks that had previously constrained growth.
Operational Efficiency
Achieved 70-90% reduction in manual reporting effort, freeing technical staff to focus on higher-value activities.
Quality and Compliance
Automated IEEE compliance validation eliminated extensive manual QA processes while improving accuracy and consistency.
Standardization at Scale
Implemented standardized processes across all manufacturing sites, enabling consistent operations and knowledge transfer.
Looking Ahead
Sustaining Digital Leadership in Manufacturing
Prolec GE Waukesha continues to work with Torsion to further streamline testing workflows and expand digital capabilities. With a robust digital foundation now in place, the team is positioned to build on these results like exploring opportunities in advanced analytics, predictive quality, and real-time monitoring to drive ongoing improvements in manufacturing performance.
This case demonstrates how targeted digital integration can turn industry constraints such as compliance pressure and testing bottlenecks into measurable gains in delivery, capacity, and quality.
This case demonstrates how targeted digital integration can turn industry constraints such as compliance pressure and testing bottlenecks into measurable gains in delivery, capacity, and quality.
