Product Quality Of High Frequency Transformer Of Company C Based On Improved Productivity Improving Research

The global electronics manufacturing industry has a medium-sized market but a large number of companies in the industry.With the market gradually becoming saturated,internal competition is becoming increasingly fierce and companies are faced with the problem of gradually increasing production costs.Small and medium-sized multi-species,low-volume manufacturing companies must consider how to control production costs,improve product quality,standardise production management and other issues,and constantly explore the company’s own potential to make targeted improvements to improve product quality to reduce unnecessary costs,so as to strive for a larger market share in the industry.This paper takes the high frequency transformer production system of C Company as the research object,with the main objective of improving the quality of high frequency transformer products,using fault tree analysis methods,fuzzy mathematical correlation theory and DOE experimental design to analyse and improve the quality problems of the products.The main work is as follows.(1)By analysing the current situation of the high frequency transformer production system and using the fault tree analysis method,the processes leading to poor inductance,poor withstand voltage and poor appearance of the transformer are identified and a fault tree is established.(2)Fuzzy reliability analysis is carried out for the processes of transformer production system.Based on the fault tree of the transformer production system,the fuzzy reliability allocation method is used to analyse the processes that affect the performance and poor appearance of the transformer,establish the fuzzy factor set and fuzzy weight set,then use the fuzzy comprehensive evaluation method to obtain the fuzzy judgment matrix of experts for each process,and finally obtain the reliability allocation failure rate and ranking results of each process of the production system by fuzzy transformation.(3)By comparing the reliability ranking results with the field data,improvements were made in two areas: risky processes and major processes.Firstly,the risk process was identified as the laser peeling process,and a fishbone diagram and Pareto diagram were used to analyse the process,and DOE experimental design and response surface design were carried out with the aid of Minitab software to derive the optimum process parameters for peeling power and peeling speed.The second aspect is to provide improvement measures for the main processes with the guidance of lean thinking,to establish 6S management processes,to design SOP standardised reference formats,to optimise jig design and to improve jig production processes.(4)Verification of the reasonableness of the process parameters of the risk process and the effectiveness of the improvement measures.The process parameters of the risk process were verified in production and it was found that the yield rate of the risk process increased from 92.94% before optimisation to 97%,an increase of 4.06%.A further comparison of the effects of the main processes,site management and product quality before and after improvement showed that the process failure rate and document error rate were significantly reduced and the product yield increased from 87.84% before improvement to 97.08%,exceeding the original target value,demonstrating the effectiveness of the improvement measures.Through the above analysis and improvement,the transformer production system has been optimised to a certain extent,the product quality yield has been significantly increased and the site management has been effectively improved,which also provides a set of methods and ideas for the company’s process quality improvement problems and provides a reference for subsequent studies.