Failure Analysis and Prevention of High-Voltage Failure of FHP Motor

This paper describes a systematic approach adopted to identify the possible causes of fractional horsepower AC motor failure and subsequent fault-proofing procedures developed using Poka-yoke concept. Seven quality control tools and Why–Why analysis are employed to determine the root cause of problem, and poka-yoke technique is used for process redesign. As a result human errors are eliminated, and improved process design led to negligible failures from the initial failure rate (4500 ppm). The whole approach is generic in nature and can be adopted to solve wide variety of industrial problems.