by :

Febian Tomy Pramadi

13105002

Outline
1.
2.
3.

1.
2.
3.

Probation Report
Organization Structure
Basic Relay Knowledge
Job Responsibility
Probation Project
( Disposal Reduction Activity )
G7L Base Crack Problem
G7L Terminal Loose Problem
G7L base dificult to take out after term.
Caulking

Organization Structure

Basic Relay Knowledge

Relay is a component which recieve input signal and

transfer signal to next device.

Contact Resistance (CR) is resistance between two contacts.
Cause of failure
CR Infinity

Dust

Fiber from operator

PBT scratch by terminal insertion

CR
CRNG
NG

CR high (unstable)
Abnormal
AbnormalTemperature
Temperaturerise
rise
CR
CRNG
NG

Foreign Mat. ( PBT scratch

Film on the contact surface

Scar on contact surface
Protein from operator
Oxide film, sulfide film, etc..

Oxide/sulfide film
Organic film

Armature Follow & Contact Pressure

1. Release condition

Armature
Follow
2. Contact ON

*AF CP (correlative)

Contact
Pressure
3. Operate perfectly

Effect to product performance

AF big

High spring load

AF low

Low contact pressure

Spring broken
OV high, armature vibration(AC Type)
E-Life NG
RV low, CR unstable

Contact Gap

CG :
Needed for switching load.
Relay which has big CG
can switch big load.
CG
Release

Operate

Effect to product performance

CG big

Big armature stroke

Cannot operate
OV high, AF low

CG small

Low insulation distance

Cannot cut arc -> Burning

Dielectric withstand voltage NG

OV, RV, Operate Time, Release Time

Operating Voltage is the voltage needed to operate relay.

(relay can operates means coil magnetic power > spring
force. )
Release Voltage is the voltage when the relay start to off
( coil magnetic power < spring force )
Operate Time between coil voltage ON and a contact ON
Release Time between coil voltage OFF and a contact OFF

Case

LED block

Coil spring
Yoke

Lead line
Mov. Block

Arc burrier
Yoke
Core
Base
Spool

Sta.term.B

Sta.term.A

Job Responsibility
Analyze and improve characteristic problem in

relay.
Analyze the possibility of part condition (out
spec part).
Testing product ( New material, special
requirement from customer, special part
condition, etc.)

Activiti
No.
es

Project Handle

G7L Base Crack and Terminal Loose Problem

G7L Base difficult to take out after term. caulking.

G7L V-Cut Terminal

G7L Moving Contact Crack Problem

G7L B Type Base Crack Problem (Yoke Assy to Base)

G8PT Stationary Terminal and Yoke Slant (Base Problem)

G8PT Contact Crack Problem (E-Life Testing and Study Dome
Design)
PTF Screw Rusty Problem (Enviromental Test)

LY2 E-Life Improvement

10 G9TA Establishment (Testing Support)

11 LYX Establishment (Support Provide Sample)

Disposal Reduction Activities

G7L

Nov
13

Dec
13

Jan
14

Feb
14

Mar
14

Part

0,05

0,03

0,04

0,03

0,01

Proces
s

0,05

0,05

M/C

0,03

0,01

0,12

0,01

Char.

0,01

Total

0,08

0,10

0,21
Target
! 0.46

0,04
0,01
List Problem G7L STD
Base crack after terminal
caulking.
Terminal loose after
terminal caulking
Base difficult to take out
after caulking

Root Cause Base Crack

Man

M/C

Bas
e

Part

Base Crack

M/C Term. Caulking

Method

Base G7L 1A T
07
Cav 1

H1

H2

Cav 2

H1

H2

Spec.

8.00 - 8.10

8.00 - 8.10

Spec.

8.00 - 8.10

8.00 - 8.10

Min

7,974

8,030

Min

8,067

8,022

Max

8,023

8,058

Max

8,101

8,098

Avg

7,996

8,046

Avg

8,08

8,05

Base crack problem in this

case happens because item H1
is below spec.

Base crack

Action : Improve item H by

tsukasa ( Finished End of
January 2014 )

Root Cause Terminal Loose

Man

M/C

Terminal
Bas
e

Part

Terminal Loose

M/C Term. Caulking

Method

Terminal Loose Problem

Term.

Item D

Spec. 0.83 - 0.89

Cav
1

G1

G2

H1

H2

Spec. 0.82 - 0.88 0.82 - 0.88 8.00 - 8.10

8.00 8.10

Cav
2

G1

Spec. 0.82 - 0.88

Min

0,830

Max

0,870

Avg

0,85

G2

H1

H2

0.82 0.88

8.00 8.10

8.00 8.10

Min

0,830

0,823

8,032

7,971

Min

0,879

0,857

8,067

8,022

Max

0,863

0,873

8,072

8,032

Max

0,907

0,890

8,101

8,098

Avg

0,84

0,85

8,05

8,01

Avg

0,89

0,87

8,08

8,05

Item G

Cavity 2
Terminal loose

Item G is bigger, so
Its make terminal
loose.

Action :
Improve item
G by tsukasa
( Finished end
of january
2014 )

Root Cause Base Difficult to take out after terminal

caulking

Man

M/C Term. Caulking

M/C

Wrong take
Method

Bas
e

Part

Base Difficult to take out

Weak

Method

No.

Angle a

44,37

44,98 45,21 44,35 36,82

45,18

44,98 45,08 44,64 36,81

44,98

45,39 44,97 45,07 36,80

49,96

45,42 45,59 49,78 36,80

C/M:
1) Provide 2 kind of
cutter
2) Provide plug & play
jig
(Improve mid of january
2014 Finished )

No
.

36,80

36,81

36,82

36,82

36,79

36,78

C3

Conclusion

for base crack problem item that we must control is

item H
For terminal loose problem item that we must control
is item G or we must control v-cut.
For base that difficult to take out after teminal
caulking we must control center to center between
cutter and center to center between base hole ( item
L ).
After 6 months in OMI :

I can learn more about PLC.

Get relationship with another dept.