項目報告投訴變頻器測試方法改進

1、 投訴變頻器測試方法改進投訴變頻器測試方法改進Improve the test concept for claim inverter Schindler | SEL | Bobo Yuan | Page 2Why we set up this PSP team為何我們成立這個為何我們成立這個PSP小組小組Background 背景背景We received 226pcs of claim VF11/22/33/44BR inverter from the Aug. 2009 to July 2010 and it should spend 40 minutes on test verify f

2、or each claim2009年8月至2010年7月共收到VF11/22/33/44BR變頻器投訴226pcs, 每臺產(chǎn)品的再測試驗證時間約40分鐘分鐘To realize Schindler Value Vision Continuously improving production and service, we set up PSP team to optimize the test process and increase the efficiency為實現(xiàn)迅達價值觀-不斷改進產(chǎn)品和服務(wù)，我們成立了PSP小組，試圖優(yōu)化測試流程,提高測試效率 Schindler | SEL | Bo

3、bo Yuan | Page 3Introducing of team member小組成員介紹小組成員介紹Team member & Function in PSP項目成員和主要職責(zé)項目成員和主要職責(zé)Photo of the team member 成員照片成員照片Established: July, 2010成立時間成立時間:2010-07 Bobo Yuan 袁懷兵Zhu Min Jun 朱民軍 Yan Zun 嚴(yán)尊Name姓名姓名Dept.部門部門Resp.職責(zé)職責(zé)Bobo Yuan 袁懷兵EED 電梯工程部Team Leader 組長Harry Zou 鄒 敏EED 電梯工程

4、部Facilitator 輔導(dǎo)員Zhu Min Jun 朱民軍QA 質(zhì)量部Testing/validate 測試/驗證Yan Zun 嚴(yán) 尊QA 質(zhì)量部Testing/validate 測試/驗證 Harry Zou 鄒 敏 Schindler | SEL | Bobo Yuan | Page 4Rough Project Plan初略項目計劃初略項目計劃Plan 計劃States 實際Item序號Content項目內(nèi)容Resp.負(fù)責(zé)人From開始時間To完成時間State狀態(tài)2010JulyAugSepOct1Project idea項目構(gòu)思Bobo Yuan7/157/31 Closed2

5、Data collect, test & validate數(shù)據(jù)收集,測試驗證Bobo Yuan8/19/30 Closed3Test reportproject report測試報告/項目報告Bobo Yuan10/610/20Closed Schindler | SEL | Bobo Yuan | Page 5PSP Action SchedulePSP 項目進度跟蹤項目進度跟蹤ItemContent July.2010 Aug.2010 Sep.2010 Oct.2010編號 內(nèi)容w28w29w30w31w32w33w34w35w36w37w38w39w40w41w421Defin

6、e the problem確定問題2Containment actions遏制行動3Initiate problem analysis初步問題分析4Finalize problem analysis最終問題分析5Optimize solution優(yōu)化解決方案6Implement solution實施解決方案7validate results驗證結(jié)果8Standardize the solution解決方案標(biāo)準(zhǔn)化 Schindler | SEL | Bobo Yuan | Page 6Step 1: Define The Problem步驟步驟1: 確定問題確定問題 Situation: As

7、per the failure information ,we noticed the failure top 4 is no display, trip error 707, trip error 708 and trip error 712/713 totally are 75% of the claim. The others are wrong claim or single case or the root cause is clear. 現(xiàn)狀：現(xiàn)狀： 根據(jù)故障現(xiàn)象,我們發(fā)現(xiàn)主要故障集中在上電無顯示,報707故障,報708故障, 報712/713故障.占總共投訴的75%,其他25%為

8、現(xiàn)場誤投訴或個案且故障原因清晰. Schindler | SEL | Bobo Yuan | Page 7Step 1: Define The Problem步驟步驟1: 確定問題確定問題Desired Reduce claim ratio 70%Saving 1,000,000 RMB/YPurpose: Analyze and find out the root cause of claim top 4 then define the improvement solution to reduce the claim ratio 70%,it should save 1000,000RMB/

9、Year after the problem be closed. 目標(biāo)：目標(biāo)：分析并定義故障率最高4項的根本原因并提出改善對策,以此降低投訴率70%, 可節(jié)省資金人民幣1,000,000元元 /年年 Schindler | SEL | Bobo Yuan | Page 8Step 2: Implement Containment actions步驟步驟2： 采取遏制行動采取遏制行動 What WhenStatus Send the engineer to field to carry out the on site investigate before we accept the claim

10、 在接受投訴前,派工程師去現(xiàn)場調(diào)查Jan-10Closed Implement the on line support before we accept the claim 在接受投訴前,做在線技術(shù)支持Jan-10Closed Release the LPCA SEL092 發(fā)LPCA SEL092May-09Closed Send the replacement to the field fleetly 給現(xiàn)場發(fā)緊急替換件May-09Closed Arrange the technical training for the fieled engineer to define the prob

11、lem quickly 給現(xiàn)場工程師進行技術(shù)培訓(xùn)以快速準(zhǔn)確確定問題點Jun-09Closed Feedback the claim data to CR&D-DR to get the technical support 向集團R&D反饋投訴數(shù)據(jù),尋求技術(shù)支持Apr-10Closed Hold a internal communicate meeting to define the process of claim technical analysis to be professional 召開內(nèi)部會議,定義投訴技術(shù)分析流程,做到響應(yīng)更快速,分析更專業(yè)Apr-10ClosedE

12、ffectiveness of action 遏制行動效果:1. The field can define the problem quickly and block the wrong claim 現(xiàn)場能快速確認(rèn)問題點,并杜絕了誤投訴.2. The technical support is well and increase the customer satisfaction 技術(shù)支持快速有效, 提高了客戶滿意度. Schindler | SEL | Bobo Yuan | Page 9Step 3: Initiate Problem Analysis步驟步驟3：初步問題分析：初步問題分析G

13、ap: 70%人力資源欠缺Sourcing problem錯誤投訴Wrong claim問題缺乏跟蹤Follow up is not Effectiveness 人人Man人為損壞Damaged by wrong handling現(xiàn)場調(diào)試不當(dāng)Wrong commissioning環(huán)環(huán)Environment產(chǎn)品結(jié)構(gòu)復(fù)雜Product frame too complex產(chǎn)品電路復(fù)雜Product hardware too complex環(huán)溫太高Environment temperature灰塵污染Dust pollution濕度太大humidity控制柜/系統(tǒng)問題Controller/System

14、 problem生產(chǎn)工具問題Tool problem軟件設(shè)計缺陷Software design problem硬件電路設(shè)計缺陷Hardware design problem生產(chǎn)設(shè)備問題Fixing problem機機Machine電子材料問題Electric components problem印板質(zhì)量問題Quality problem on PCBA選型問題Wrong type現(xiàn)場未可靠接地Grounding issue無指導(dǎo)文件WI is missing結(jié)構(gòu)設(shè)計缺陷Frame design problem料料Material法法Process調(diào)試經(jīng)驗欠缺Not professional o

15、n commissioning新人作業(yè)Done by new comer問題分析/解決能力不夠Not professional on problem analysis/solving未理解作業(yè)流程Do not understand the working process批次性問題the quality problem with some special produce duration現(xiàn)場安裝不當(dāng)Wrong installation指導(dǎo)文件不清晰WI is not clear指導(dǎo)文件有誤Mistake on WI Schindler | SEL | Bobo Yuan | Page 10Ste

16、p 3: Initiate Problem Analysis步驟步驟3：初步問題分析：初步問題分析Fix the problem-Product itself 確定問題點來源確定問題點來源-產(chǎn)品本身問題產(chǎn)品本身問題Possible CauseWhat had been doneWhat root cause was confirmedResultthe quality problem of the PCBA board with some special produce duration 印板批次性質(zhì)量問題?check the Serial No.of all the defective bo

17、ard檢查所有故障變頻器的印板的序列號the Serial No. is dispersive and we do not find out the problem focus on some special duration發(fā)現(xiàn)印板的制造周期分散,未出現(xiàn)故障印板集中出現(xiàn)在某一特定制造周期現(xiàn)象Nthe quality problem of the components with some special produce duration故障元件批次性質(zhì)量問題?check the Serial No.of all the defective components檢查所有故障變頻器的元件的序列號t

18、he Serial No. is dispersive and we do not find out the problem focus on some special duration發(fā)現(xiàn)元件的制造周期分散,未出現(xiàn)故障元件集中出現(xiàn)在某一特定制造周期現(xiàn)象NManufacture problem生產(chǎn)制造問題?check the assembly process檢查產(chǎn)品生產(chǎn)組裝過程the assembly process is ok組裝過程正常Nthe solder problme of the components元件焊接問題?re-soldering the pin of the defeci

19、tve components重新焊接一次相關(guān)元件的引腳the fault is not disappear故障依然存在Ndue to the incorrect system application ?系統(tǒng)應(yīng)用問題導(dǎo)致?lián)p壞?Check the relevant TK documents and carrty out the filed checking檢查相關(guān)TK文件并現(xiàn)場調(diào)查do not find out the problem due to application.未發(fā)現(xiàn)是由于錯誤的應(yīng)用造成的.Npollution problem on the components元件污染問題?check

20、 the situation of the components檢查故障元件的污染狀況we do not find out the pollution 未發(fā)現(xiàn)明顯的污染問題Nthe quality/design problem?材料質(zhì)量/設(shè)計缺陷?see the following page見下頁see the following page見下頁Y Schindler | SEL | Bobo Yuan | Page 11Step 4: Finalize Problem Analysis步驟步驟4: 最終問題分析最終問題分析 For No display error 針對上電無顯示的故障針對上

21、電無顯示的故障We noticed all this kind of failure only happed on VF11BR 我們注意到該故障僅僅發(fā)生在VF11BR變頻器上We find out the R500,R501,R502(Id. 430355(RESISTOR 15.0 OHM 2% 3W NON INDUCTIVE) are burnt and in open circuit on PP11 board 59400651. 我們發(fā)現(xiàn)在PP11印板上的電阻R500,R501,R502處于開路狀態(tài)且有燒毀的痕跡.Also as check and feedback with th

22、e field engineer, we get the information that almost all of the failure happened on the commissioning period. The fact is during this duration, the inverter was power on/off continually, so the inrush/charge current via the resistors continually and caused the resistor burnt finally. 通過調(diào)查和現(xiàn)場確認(rèn),這種故障幾

23、乎都發(fā)上在電梯調(diào)試階段,一種可以遵循的現(xiàn)象是,在這個階段,變頻器會被頻繁的上電/掉電,所以啟動電流和涌流會頻繁通過該電阻,最終導(dǎo)致該電阻過流/過功率損壞.We check the spec and find out the power rating of the resistor is not enough. 我們檢查該電阻的規(guī)格發(fā)現(xiàn)現(xiàn)有的電阻功率不夠. Schindler | SEL | Bobo Yuan | Page 12Step 4: Finalize Problem Analysis步驟步驟4: 最終問題分析最終問題分析 The Root Cause 根本原因根本原因 The typ

24、e of the resistor is not correct and caused it was failed as the normal working 電阻電阻R501, R502, R503選型不當(dāng)選型不當(dāng),造成在正常工作中過功率燒毀造成在正常工作中過功率燒毀For No display error 針對上電無顯示的故障針對上電無顯示的故障 Schindler | SEL | Bobo Yuan | Page 13Step 4: Finalize Problem Analysis步驟步驟4: 最終問題分析最終問題分析 For trip Error code 707 (SGRW Fai

25、lure)針對顯示故障代碼針對顯示故障代碼707According to the summary of variodyn claim database and the feedback from field, the error code 707(SGRW Failure) occurs high frequency on variodyn VF11BR, VF22BR and VF33BR (a relay is used on SGRW circuit loop) but a fat lot on above variodyn VF44BR (a contactor is used on

26、SGRW circuit loop), the relevant testing carry out accordingly to try to find out the root cause of this issue and improve the product quality.707故障主要發(fā)生在VF11/22/33BR產(chǎn)品上發(fā)生頻率比較高,但在VF44BR及以上功率等級的變頻器發(fā)生率則幾乎為零,我們發(fā)現(xiàn)主要區(qū)別在于VF11/22/33BR在相關(guān)電路上使用的是繼電器,而VF44BR及以上功率等級的變頻器則使用的是接觸器實現(xiàn)相同的功能.The location of the SGRW R

27、elay繼電器在印板上的位置 SGRW circuit 繼電器控制電路 Schindler | SEL | Bobo Yuan | Page 14Step 4: Finalize Problem Analysis步驟步驟4: 最終問題分析最終問題分析For trip Error code 707 (SGRW Failure)針對顯示故障代碼針對顯示故障代碼707The Root CauseWe put a thin wiring and fix the NC contact metal point 11 and 12 of the SGRW Relay, then make the test

28、process, We find out that the fault disappear, that mean the original situation of the relay is not stable.根本原因根本原因:初始狀態(tài)下初始狀態(tài)下,繼電器常閉觸點未能可靠閉合繼電器常閉觸點未能可靠閉合 Schindler | SEL | Bobo Yuan | Page 15Step 4: Finalize Problem Analysis步驟步驟4: 最終問題分析最終問題分析 For trip Error code 708(SGR/SH Failure ) 針對顯示故障代碼針對顯示故障代

29、碼708 When the drive trip 708 we noticed the IC 301 on Variocon board has been damaged (in open circuit or in short circuit) and DC-Link test failed. 當(dāng)變頻器顯示708故障代碼時, 我們注意到Variocon印板上的IC301已經(jīng)損壞(處于開路或短路狀態(tài))且直流環(huán)測試不能通過. After analysis the hardware we noticed the IC301 and relevant components do not be pro

30、tected reliably 通過分析相關(guān)電路,我們發(fā)現(xiàn)IC301和相關(guān)元件未被可靠電路保護.The location of the IC301 on Variocon IC301在Variocon印板上的位置 Schindler | SEL | Bobo Yuan | Page 16Step 4: Finalize Problem Analysis步驟步驟4: 最終問題分析最終問題分析 For trip Error code 708(SGR/SH Failure ) 針對顯示故障代碼針對顯示故障代碼708 The Root Cause 根本原因根本原因 Due to the defect

31、of the hardware design and caused the variocon board damaged.由于線路的設(shè)計缺陷造成由于線路的設(shè)計缺陷造成Variocon印板上的零件損壞從而報印板上的零件損壞從而報708故障故障 Schindler | SEL | Bobo Yuan | Page 17Step 4: Finalize Problem Analysis步驟步驟4: 最終問題分析最終問題分析 For trip Error code 712(Power Electronic Failure ) 針對顯示故障代碼針對顯示故障代碼712 We noticed the pro

32、blem happened on VF11/22/33/44BR and they has the similar trigger circuit of IGBT. VF11/22/33/44BR變頻器均可能發(fā)生該故障,因為他們有類似的IGBT驅(qū)動電路. After analysis the hardware we noticed some components has been damaged on PCBA 通過分析投訴變頻器,我們發(fā)現(xiàn)印板上的IGBT驅(qū)動電路的部分元件(電阻/電容等)損壞.The Root CauseSome components (resistor/ capacitor

33、) on the IGBT trigger circuit defective due to the power rating is not enough.根本原因根本原因:IGBT驅(qū)動電路里面部分元件驅(qū)動電路里面部分元件(電阻電阻/電容電容)功率不夠功率不夠,造成元件過功率損壞造成元件過功率損壞 Schindler | SEL | Bobo Yuan | Page 18Step 5: Optimize Solution步驟步驟5 ：完善解決方案：完善解決方案No.ItemRoot CauseSolutionEffectivenessCostTimeFeasibilityScore5(Weig

34、ht)4251No display上電無顯示The type of the resistor is not correct電阻選型不當(dāng) Change the risistor for the claim inverter給故障變頻器更換電阻413450Change the PP11 board for the claim inverter給故障變頻器更換印板532566Send the replacement to the field給現(xiàn)場發(fā)緊急替換件513444Re-design the PP11 PCBA重新設(shè)計PP11印板5335682Trip error 707顯示707故障The S

35、GRW relay can not work properly at original situation初始狀態(tài)下,繼電器常閉觸點未能可靠閉合Change the SGRW Relay for the claim inverter給故障變頻器更換繼電器513444Change the Skiip board for the claim inverter給故障變頻器更換印板532566Send the replacement to the field給現(xiàn)場發(fā)緊急替換件513444Re-design the PCBA重新設(shè)計印板533568 Schindler | SEL | Bobo Yuan

36、 | Page 19Step 5: Optimize Solution步驟步驟5 ：完善解決方案：完善解決方案No.ItemRoot CauseSolutionEffectivenessCostTimeFeasibilityTotal5(Weight)425 3Trip error 708顯示708故障Due to the defect of the hardware design and caused the variocon board damaged.由于線路的設(shè)計缺陷造成Variocon印板上的零件損壞Change the Variocon board for the claim in

37、verter 給已經(jīng)損壞的變頻器更換Variocon印板和改線433353Change the wiring for the field inverter 針對現(xiàn)場還未損壞的變頻器改線433458Send the replacement to the field給現(xiàn)場發(fā)緊急替換件513444Take the traiing for the fieled to how to rewing 計劃對現(xiàn)場工程師針對該現(xiàn)象進行培訓(xùn)5345704Trip error 712顯示712故障Some components defective due to the power rating is not eno

38、ugh.部分元件功率不夠,造成元件過功率損壞Change the board for the claim inverter給已經(jīng)損壞的變頻器更換印板133233Send the replacement to the field給現(xiàn)場發(fā)緊急替換件513444Re-design the PCBA重新設(shè)計印板534570 Schindler | SEL | Bobo Yuan | Page 20Step 6: Implement Solutions步驟步驟6 ：實施解決方案：實施解決方案 Schindler | SEL | Bobo Yuan | Page 21Step 7: Verify Resu

39、lts步驟步驟7 ：驗證結(jié)果：驗證結(jié)果14%35%3%23%2%71% Reduce!2% Schindler | SEL | Bobo Yuan | Page 22Step 8: Standardize The Solutions步驟步驟8 ：使解決方案標(biāo)準(zhǔn)化：使解決方案標(biāo)準(zhǔn)化Release relevant technical documentations and KAs 發(fā)布并導(dǎo)入相關(guān)的技術(shù)文件和發(fā)布并導(dǎo)入相關(guān)的技術(shù)文件和KA Schindler | SEL | Bobo Yuan | Page 23Step 8: Standardize The Solutions步驟步驟8 ：使解決方案標(biāo)準(zhǔn)化：使解決方案標(biāo)準(zhǔn)化 Define the process with CR&D-DR to improvement the quality of the product.