Shanghai Haoyue Electric Co.
, Ltd
SHANGHAI HAOYE CAPACTIORS CO.,LTD
Rectification Report
1. Basic information:
Customer: NIDEC customer in Slovakia Date of occurrence: October 21, 2024
Title: Slovakia NIDEC Customer Feedback MKP 20uF Capacitor No Capacity Analysis
Improvement Report
Product model: Report No.: 2024-11-01
MKP 450V*20μF±5%
2. Problem description:
On October 21, 2024, NIDEC customers in Slovakia reported that the capacitance of
the Haoyue MKP product 20uF/450v (customer material number: 2253312) is low. The
defective capacitor has been received and retested to confirm that there is no capacitance
value. The capacitor was produced in January 2024, and the specific photos are as follows:
Figure (1) Identification of Defective Products (2) Testing of Defective Products
3. Establish a group:
Group members department position
Chu Jin Sheng Anhui factory Factory Manager
Liu Chengguo Process Department Craft expert
Chu Can Quality Department Quality Manager
Cheng Ran Process Department Process Engineer
Wang Hao Quality Department Quality Engineer
Cao Peihua Manufacturing Department Shift Leader
4. Encirclement measures:
person Completion
content result
liable time
1. Inspect the company's Liu 5000 units of inventory have
November
inventory of work in progress Tongxin been frozen and require full
5th
products g performance retesting
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Shanghai Haoyue Electric Co., Ltd
SHANGHAI HAOYE CAPACTIORS CO.,LTD
Qi
2. Identify products in transit Zhanyin Completed No products in transit
g
3. Check the products at the
/ / /
customer's location
5. Cause analysis:
5.1 Product testing:
Figure (3) Product Direct Test (No Capacity NG)
5.2 Dissection of Defective Products
Figure (4) Defective product: ineffective lead out
5.3. Cause analysis:
1) Causes:
From the anatomical phenomenon of defective products, it can be seen that a lead
wire was not effectively led out, and the gold on the back of the lid was pressed against it
Belonging to the film. Mainly due to the overall short lead size, the lid assembly staff
were unable to thread both leads in
Inside the hole of the lid; The employees who subsequently trimmed the wire ends did
not pick out the products with exposed wireless ends as defective products, resulting in
Defective products flow into the finished product testing process.
2）Reason for outflow:
A. The top of the lead wire is on the metal sheet on the back of the cover, and the lead
out electrode is already conductive, but it is a poor contact. There may be equipment
misjudgment within a short period of time (1.5 seconds), and it cannot be guaranteed that
there will be no leakage;
B. Reproduction of defects, produce 20 test samples according to the type of
defective product; Conduct the experiment in two groups:
A group of our finished product testing equipment was tested normally for 1.5
seconds, with 9 devices judged as having no capacity NG and 1 device judged as qualified;
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Shanghai Haoyue Electric Co., Ltd
SHANGHAI HAOYE CAPACTIORS CO.,LTD
The other group used our finished product testing equipment and extended the testing time
to 2 seconds for stricter testing. All 10 products were judged to have NG pressure
resistance and capacity.
Figure (6) Equipment withstand voltage time extended by 2 seconds, retested (both
withstand voltage and capacity fail)
5.4 Summary of Reasons:
The lead size is short, and it is not effectively led out from the cover hole. It is
placed on the metal sheet on the back of the cover and connected virtually
Causing defective products to flow into the client.
6. Corrective measures:
6.1. Do not generate:
1) Adjust the internal lead size of the capacitor: Extend the length of the two leads by 2mm
on the existing basis
——Technology Department Liu Chengguo - Completed on July 2, 2024
--Figure (7) Before Lead Extension Figure (8) After Lead Extension
2) Add a wire pressing process after the lid is assembled: After the lid is assembled, two
wire ends must be bent onto the lid.
——Technology Department Liu Chengguo - Completed on July 2, 2024
Figure (9) Unburned leads Figure (10) After bent leads
3) Add inspection requirements for the construction line end process: It is required that the
wire cutting personnel must pick out products with wireless joints outside the welding
points as scrap and provide feedback to the previous assembly process.
——Technology Department Liu Chengguo - Completed on July 2, 2024
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Shanghai Haoyue Electric Co., Ltd
SHANGHAI HAOYE CAPACTIORS CO.,LTD
Figure (11) Before lead elongation and without bending Figure (12) After lead elongation
and bending
Figure (13) Training Attendance Sheet
6.2. No leakage:
Extend the testing time for finished products from the current 1.5s to 2s to ensure effective
detection of defective products.
——Technology Department Liu Chengguo - Completed on July 2, 2024
Figure (14) Improved SOP
7. Verification of measures
After the improved products are sent to your company, please track and verify them.
Thank you!
8. Unite and wish success together
make Chu Can 2024.11.1
approval Chu Jin Sheng 2024.11.1
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