How Does Geyue Electric Reduce Product Failure Rate To Zero?

Preface

Previously, customers of our Geyue Electric compensator cabinets complained about overheating power capacitors, loud noise from reactors, and a failure rate stuck at 0.7%. Last year, we implemented a certification system for all employees, held quarterly skills competitions for engineers, and opened up a comprehensive promotional path. Now, the torque pass rate for capacitor terminals is 100%, the reactor winding tolerance is reduced to ±0.1 mm, and the overall cabinet failure rate has been reduced to 0.07%. Customer complaints have been eliminated.

How to Cultivate Zero-error Technicians?

The high-voltage electrician certification standard, developed jointly with the Ministry of Human Resources and Social Security, includes a 200-hour theoretical course covering capacitor dielectric properties and reactor core principles, as well as 300 hours of practical training. Laser measurement equipment is used for assessment. A reactor winding tolerance exceeding 0.1 mm results in a failure; a power capacitor terminal torque deviation exceeding 1 Nm results in a failure. After systematic training, all six engineers received national professional qualification certificates, significantly improving the standardization of assembly operations in the workshop.

The quarterly skills competition features two core events: capacitor assembly and reactor winding. The capacitor assembly competition requires competitors to complete 20 sets of terminal tightening within 30 minutes. A digital torque wrench is used to ensure that each connection point remains within the 25 ± 1 Nm range. Infrared thermal imaging monitors the terminal temperature rise in real time, and those exceeding the temperature limit are eliminated. The reactor winding competition uses 0.15 mm enameled wire to continuously wind 42 layers on the nanocrystalline iron core, with a tolerance requirement of ≤0.1 mm (1/70 of a hair). The 3D laser scanner generates a thermal map of the winding gap every 5 seconds, and a red light warning will be triggered if the deviation exceeds 0.05 mm.

2023 Promotion Statistics:

A total of 37 employees were promoted throughout the year, with the proportion of technicians and above increasing to 63%. Engineer Zhang's team improved the process for producing power capacitor explosion-proof membranes, increasing the lifespan in salt spray tests from 3,000 hours to 6,000 hours. Engineer Wang optimized the reactor painting process, resulting in annual cost savings of $120,000. A total of 17 process improvements were implemented throughout the year, resulting in an 89% year-on-year decrease in the failure rate. Promotion ceremonies are held quarterly, and the promotion list is updated on the workshop bulletin board in real time. Employee ID card color bands vary by level (junior workers are blue, technicians are gold). A clear mechanism for transferring technological achievements is in place: each effective improvement is rewarded to the team at 5% of annual revenue, with individual bonuses reaching up to $20,000 per year.

Core Data for Quality Improvement

The dispersion of reactor inductance has been reduced from 3% to 1.5%, power capacitor terminal overheating failures have been eliminated, and the entire cabinet's withstand voltage test pass rate has reached 99.98%. Third-party testing has confirmed that the capacitors maintained an insulation resistance of 15 GΩ after a 6,000-hour salt spray test, and the reactor windings showed no corrosion.