Quality Management

As a safety product, the thermal protector is a component for overheat protection when an abnormality occurs in electronic and electrical products, and has extremely high reliability requirements. The problem of reliability can not be completely solved by picking it up. It involves the specific working conditions of the customer, the structural design of the product itself, the material, the stability of performance and other aspects. It is a very complex system problem. In terms of improving product reliability, after nearly ten years of polishing, it has gradually formed its own six standards. Many models can reach the defective rate of 50PPM in the process of client use, especially the defective rate of HKW9700-B series products is less than 20PPM.

First customer demand analysis

The thermal protector is installed on the customer's whole machine. The product application solutions of different industries and different customers have different environments and requirements. If you do not understand the various application scenarios of the product, even if the product itself is in line with the national standard or UL, TUV and other standards. In the application process of the product, there will also be more than N unexpected conditions, resulting in the failure to achieve the purpose of protection.
 
For example, when applied to the external rotor fan industry, after many customers install the protector into the stator, the entire stator coil will be vacuumed and painted. Some vacuuming pressures will reach-0.085MPa. Insulating paint can easily penetrate into the product through the gap of the shell or the gap of the wire core. If the amount of dipping paint is large and reaches the contact center, the product will directly fail. Many standards do not have this provision, if you do not take into account this problem, even in line with the certification standards of the product will be scrapped, increase the probability of the client to use the repair, reduce the production efficiency, improve the production cost. In response to this problem, after years of research and development, our company has finally developed a 17AM series thermal protector that can prevent product failure in the vacuum pumping and painting process.
 
Therefore, to improve reliability, it is necessary to understand the actual use of customers, and these problems must be taken into account in the product design and production process, so that the probability of defective products will be reduced.

Second Reliability Design Management

Good products are designed and manufactured, not inspected and selected. If the quantity of products is selected through inspection, it will not only have low efficiency and high cost, but also cannot guarantee that the selected products will have stable performance during use.
 
Reliability design management is divided into seven parts: reliability review and project management, product design training, process design training, CHKLIST development, test report template, design report template, review and reward management. First of all, feasibility evaluation is a very important first link. If reliability evaluation is not carried out at the beginning of product design, and adjustment is carried out when the structure design is good and the mold is determined, it is impossible to mend the fold after the sheep is lost, and the price paid is also very high. Product design training and process design training are to ensure that research and development personnel can take reliability issues into account in the design process and realize the landing of reliability design; the establishment of the checklist is to prevent R & D personnel from omitting problems that should be considered in the design process. The test report and the design report template are designed to make the whole process flow and systematize, and will not cause operation deformation due to personnel changes. The review and reward management is to link the reliability design and performance of R & D personnel, and to ensure the importance of R & D personnel to reliability from the system.

Sixth Product Data Management Platform

Thermal protector products are composed of many parts. Whether each part can meet the design requirements directly determines the reliability of the protector. Therefore, Ann attaches great importance to the selection and certification of materials. This link is divided into six parts: material selection certification replacement process, material inspection process, material problem feedback and processing process, material selection instruction and preferred library, material customization control process, and supplier certification management process.
 
In the focus of the control of parts, we pay more attention to the selection of suppliers certification link. After all, we are not experts in parts production, and we cannot control the quality of incoming materials by purchasing higher-end testing equipment than suppliers. Therefore, our philosophy is to give professional things to professional people and choose suppliers with strict system control to cooperate.
 
The introduction of suppliers is divided into four levels. The first is to make a preliminary understanding of the basic information of suppliers such as registered capital, annual output value and number of employees. The second review whether the supplier meets the system certification such as ISO9001 and whether the product meets the international standards such as UL and TUV. The third part examines the supplier's product line site management, the company's reputation in the industry, service, typical customers, etc. The fourth examines the development prospect and growth of suppliers, whether it can meet all aspects of the company's future development needs, such as technology leadership, the ability to supply more large quantities, and the ability to control the quality of new product supply. After more than ten years of unremitting efforts, we have always kept in mind the corporate mission of providing customers with reliable products, making customers' products safer, and making human life more secure. We have created a complete set of product certification system for safety components and won the high recognition of major manufacturers around the world.

Fourth assembly reliability management

This includes part combination design specifications, incoming inspection specifications, outsourcing inspection specifications, process operation instructions, key process parameter control and automated production methods. At present, we focus on automated production methods, and solidify the existing manual production process requirements through automated equipment to reduce the uncertainty caused by manual operation. In the future, we will unswervingly implement the strategic policy of production automation into every process of product production.
 
In the production and assembly of bimetallic sheets for core components, we have formulated documents such as "Double Pieces Chong Operation Instruction", "Temperature and Humidity Control Specification", "Production Experiment Process Card" and "Double Pieces Sorting Operation Instruction" to standardize the operation process, control key parameters and strictly control the trial production before mass production. Put the control link in advance to prevent problems in the later period and make selections.
 

Fifth Failure Analysis Management

The failure of the thermal protector in the client is an opportunity for us to further improve the reliability. Solving the failure problem of the client allows us to prevent defects and fill leaks in time. The more cases of successful failure, the lower the probability of failure in the future.
 
The process of failure analysis is divided into collecting failure environmental information for failure analysis scheme design, collecting failure samples for appearance inspection first, and carrying out comprehensive test in combination with the analysis scheme. After confirming the failure of the samples, the samples are unsealed and stripped to find the failure point. First, physical analysis is carried out to determine the failure mechanism, then corrective measures are formulated, and then the results are verified.

Fourth assembly reliability management

All documents, drawings and specifications to improve reliability are finally realized by an effective data management platform. Document management includes product documentation, device documentation, production documentation, and training documentation; engineering change management includes change materials, change documentation, attribute changes, and change impact analysis. These data are shared with relevant department employees according to the authorization level, so that they can view the data in time to assist them in their work.
 
All documents, drawings and specifications to improve reliability are finally realized by an effective data management platform. Document management includes product documentation, device documentation, production documentation, and training documentation; engineering change management includes change materials, change documentation, attribute changes, and change impact analysis. These data are shared with relevant department employees according to the authorization level, so that they can view the data in time to assist them in their work. Improving the reliability of products is a systematic project and a difficult process of continuous improvement. It needs the highest level of the company to attach great importance to it. There are so many departments and links involved that it is not possible for any department or individual to complete it alone. Therefore, in the establishment of the whole system, the general manager of the company has been devoting a lot of time and energy to ensure the effective implementation and improvement of the system by making a hard fortress, fighting a dull battle, and steadily fighting step by step.