越南露通机电有限公司
Vietnam Rotong Electro-Mechanics Co., Ltd
Check Jam test after assy tool #4, #5
Motor sample #1
Motor sample #2
 Jam test for tool #4 has passed
 Jam test for tool #5 has Fail
Motor sample #3
742670011电机分析
742670011motor analysis
01
02
03
客户问题反馈 customer
problem feedback
原因分析 cause analysis
改善措施 Improvements
01
客户问题反馈 Customer problem feedback
1
23年4月22日收到客户反馈我司23年4月10日生产的742670011马达，在贵司装配发现马达不转现象，不良率：
5/132
23年4月24日贵司的SQE: Peter, NPI:Felix到我司现场确认不良品
On April 22, 23, we received customer feedback. The 742670011 motor produced by our company on April 10, 23,
was assembled in your company and found that the motor did not turn. The defective rate: 5/132
Vietnam Rotong Electro-Mechanics Co., Ltd
On April 24, 23, your company's SQE: Peter, NPI: Felix came to our company to confirm
the defective products
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
02-1
742670011 motor analysis 电机分析
马达外观良好无刮擦、破损现象，各零部件完整未发
现异常The appearance of the motor is good without
scratches or damage, and all parts are intact and no
abnormalities are found
引出线，信号线没有发现断线，线伤情
况There is no disconnection or line
damage in the lead-out line and signal
line
1
用手转动马达没有卡顿情况Turn the
motor by hand without jamming
Check the appearance of the defective motor, no abnormalities are found in the good appearance, and
there is no jamming of the hand-rotated motor
对不良马达进行外观确认，外观良好未发现异常，手旋转马达没有卡顿情况。
Vietnam Rotong Electro-Mechanics Co., Ltd
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
02-2
742670011 motor analysis 电机分析
图1测试视频 Figure 1
Test video
Retest the motor with the customer's
battery pack The motor does not start,
and the LED flashes several times用
客户电池包复测马达马达不启动，LED
闪烁多次
1
图2 Figure 2
Production line comprehensive
test retest motor, equipment
alarm 产线综合测试复测马达，
设备报警
After finding that the motor looks normal:
1. Use the customer's controller and battery pack to retest the bad motor. The motor will not start, and the LED light of the controller will keep flashing until the battery pack
is taken out and the power is turned off. The LED light will stop flashing, as shown in Figure 1.
2. Use the detection equipment of the production line to re-test the defective products, the equipment will alarm, and the screen of the equipment will show that the motor
does not rotate due to poor performance, as shown in Figure 2.
According to the above phenomenon, it can be locked that the reason why the motor does not start is the PCB board problem;
ourRotong
testing Electro-Mechanics
equipment has the ability
to
Vietnam
Co., Ltd
detect defective products.发现马达外观无异常后：
Nhon Trach III Industrial Park, Nhon rach District, Dong
1、使用客户控制器和电池包对不良马达进行复测，马达不启动，控制器LED灯一直不停闪烁，直到取出电池包断电后，LED灯才会停止闪烁，见图1所示。
Nai Province
2、使用产线的检测设备对不良品进行复测，设备报警，设备屏幕显示性能不良马达不转，见图2所示。
02-3
742670011 motor analysis 电机分析
1
The actual measurement of the distance between the
rotor magnet and Hall passed the test转子磁铁与霍尔
间距实测合格
After suspecting that the problem of the motor not starting was on the PCB board, our company checked and retested the
distance between the Hall board and the magnet. The actual measurements are all in a qualified state, the specification
requires 2.1±0.25mm, and the actual measurements are 2.14, 2.09, and 2.11mm.
怀疑马达不启动的问题出在PCB板上后，我司对霍尔板与磁铁之间的间距进行了排查复测。实测都是合格状态，规格要求
2.1±0.25mm，实测2.14、2.09、2.11mm。
Vietnam Rotong Electro-Mechanics Co., Ltd
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
02-4
1
742670011 Analysis conclusion 分析结论
图2
Figure 2
图1
Figure 1
No abnormalities were
found in the
appearance of Hall
components
霍尔元器件外观未发现
异常
Use a multimeter to detect the
hall, and the three halls of the
qualified PCB board are all
powered on用万用表检测霍尔，
合格的PCB板3个霍尔都是通电状
图2
态
Defective PCB board, 3
halls are not powered on
during detection不良品PCB
板，检测时3个霍尔没有通
电
Disassemble the motor and check the status of the PCB board;
1. There is no obvious damage to the components of the PCB board. The components are in good condition and no abnormalities are found, as shown in
Figure 1.
2. Conduct power-on detection on the defective PCB board, check whether the Hall is powered on, and find that the three Halls are not powered on.
Compared with the normal PCB board, the test results are significantly different, as shown in Figure
将马达分拆，检查PCB 板状态；
Vietnam Rotong Electro-Mechanics Co., Ltd
1、PCB板各元器件没有发现明显破损现象，未发现异常，见图1所示。
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
2、对不良PCB 板进行通电检测，检查霍尔是否通电，检测发现3个霍尔都没有通电，对比正常的PCB板，测试结果有明显差异，见图2所示。
02-5
1
742670011 Analysis conclusion 分析结论
表面有划痕
图1
Figure 1
图
2Figure
2
有损伤
痕迹
3. Continue to analyze why the three Halls are not powered on at the same time, and find that the 101 resistor at the R4 position is not powered on, and
at the same time, wear and scratch marks are found on the surface of 101, as shown in Figure 1;
Connect R4 with an enameled wire for reverse verification, and retest the 3 Halls of the defective product again, and the 3 Halls are all in a qualified
power-on state, as shown in Figure 2.
From this, it can be explained that the 101 resistance components are damaged, resulting in the failure of power to the 3 Halls, resulting in the motor not
starting
3、继续分析为什么3个霍尔同时不通电，发现R4位置101电阻不通电，同时在101表面发现磨损、刮伤痕迹，见图1所示；
Vietnam Rotong Electro-Mechanics Co., Ltd
将R4处使用一根漆包线连接起来反向验证，再次复测不良品的3个霍尔，3个霍尔都是合格通电状态，见图2所示见图2所示，
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
由此可以说明：VCC 101电阻元器件损坏，导致了3个霍尔不通电，致使马达不启动
02-6
1
742670011 Analysis conclusion 分析结论
图1
Figure 1
检查PCB板物
料元器件良好没
有破损，开裂情
况
图
2Figure
2
检查产线压装PCB板工装没发现问题，
工装有避空霍尔元器件
After the inspection found that the 101 resistor at the R4 position was not energized, and the 101 resistor components were damaged, our company
continued to check the inventory material PCB board and production line tooling;
1. Check 80pcs of PCB boards in stock and find no damage or cracking of defective components.
2. Check the tooling on the production line, the tooling should avoid the Hall components without the risk of crushing the Hall components
In summary, there is no problem in excluding materials and production tooling
检查发现VCC R4位置101电阻不通电，101电阻元器件损坏后，我司继续对库存物料PCB板和产线工装进行排查；
Vietnam Rotong Electro-Mechanics Co., Ltd
1、 使用电子放大镜对库存PCB板进行检查80PCS未发现不良元器件有破损开裂情况.
Nhon Trach III Industrial Park, Nhon rach District, Dong
2、检查产线上的工装， 工装有避空霍尔元器件没有压伤霍尔元器件的风险
Nai Province
综上排除物料来料不良和生产线工装异常导致霍尔元器件损坏。
02-7
1
742670011 Analysis conclusion 分析结论
图1
Figure 1
图2
Figure 2
Further analysis of why Hall is not powered on:
1. Check the process documents and find that the process manual requires our company to use a caliper to conduct a 100% full inspection of the distance between the Hall and the magnet before
packing the finished product. Our company also followed this requirement during the trial production on the same day, as shown in Figure 1. Show
2. After the production line inspection is completed, because it is a critical dimension, our trial production special inspection team used a feeler gauge to conduct a 100% inspection of the motor
Hall clearance, as shown in Figure 2
3. Judging from the defective rate of 5/30 reported by your company and the fact that your company participated in the whole process of guiding and auditing during the trial production process at
that time, the defective ratio is too large. Our production line testing machine will not fail to detect it with 100% full inspection. How bad is it? At the same time, your company’s personnel
confirmed with us in every process on site, so it is ruled out that the Hall defect is caused in the early stage of the production process, and it is determined that the Hall defect is caused in the later
stage of production.
To sum up, it can be shown that the reason for the poor Hall effect is that our company used a caliper to test the Hall plate spacing 100% before packing the finished product, and the Hall plate
gap was caused by the trial production inspection team using a feeler gauge to test the Hall spacing. Defective, the motor will not start when it is running, and the motor has been packed in a
finished product at this time, so the defective product cannot be identified from our company, and finally flows into the customer.
进一步分析为什么VCC 101电阻会出现损坏情况：
1、检查工艺文件，发现工序手册要求我司在成品装箱前对霍尔与磁铁间距要使用卡尺进行百分百全检，当天试产时我司也是按照这个要求在执行，见图1所示
2、产线检验完成后，由于是关键尺寸，我司试产专检小组又使用了塞尺对马达霍尔间隙进行了百分百检测，见图2所示
3、从贵司反馈的不良率5/30和当时的试产过程中贵司有全程参与指导审核来看，不良比例太大我司产线测试机百分百全检不会检验不出来这么多不良、同时现场每一道工序贵司人员都有和我们一起确认，来料抽查没有问题，产
Vietnam Rotong Electro-Mechanics Co., Ltd
线工装也没有问题，所以排除是在生产过程前期导致的霍尔不良，判定是在生产后期造成的霍尔不良。
Nhon Trach III Industrial Park, Nhon rach District, Dong
综上情况可以说明，VCC 101电阻损坏的原因是我司在成品装箱前使用卡尺对霍尔板间距百分百测试时、以及试产专检小组用塞尺检验霍尔间距时导致的101电阻损坏，最终致使马达运行时不启动，而此时马达已经成品装箱，
Nai Province
所以导致不良品无法从我司识别出来，最终流入客户处。
02-8
742670011 Analysis conclusion 分析结论
1
When the finished motor of our company is delivered to your company, the motor 101 resistance element device
is naked outside. See the red circle above the picture above, please pay attention to avoiding the position of the
position of the position during the assembly process to avoid causing the cause Risk of injury.我司的成品马达装
配完交付给贵司的时候，马达101电阻元器件是裸露在外面的，见上图红圈所示，请贵司在装配过程中注意避空该
Vietnam Rotong Electro-Mechanics Co., Ltd
Nhon Trach III Industrial Park, Nhon rach District, Dong
位置元器件，避免造成损伤风险。
Nai Province
02-9
分析结论: Analysis conclusion
1
The root cause: when the caliper was used to test the Hall spacing 100% before packing the finished motor, and
when the trial production special inspection team used the feeler gauge to check the Hall spacing 100%, the
misoperation of the personnel caused the heads of the feeler gauge and the caliper to be in contact with each other.
The contact of the Hall components caused varying degrees of damage to the Hall, and eventually the Hall was not
powered on, and the motor did not start when it was running.
Cause of outflow: Hall damage occurred before the finished product was packed, and at this time, after the Hall
spacing was inspected, the finished product was packed according to the process flow, and the process flow did
not require retesting Hall performance, so the defective product could not Identified from our company, and finally
flowed into the customer
根本原因：成品马达装箱前使用卡尺对霍尔间距百分百测试时、以及试产专检小组用塞尺百分百检验霍尔间距时，
人员误操作导致塞尺和卡尺的头部与霍尔元器件接触，导致霍尔板VCC 101电阻损伤，VCC无法供电，最终霍尔不
通电，马达运行时不启动，
流出原因：霍尔损伤的情况出现在成品装箱前，而此时马达检验好霍尔间距后，按照工艺流程已经成品装箱，工艺
流程没有再次测试霍尔性能的要求，所以导致不良品无法从我司识别出来，最终流入客户处。
Vietnam Rotong Electro-Mechanics Co., Ltd
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
03-1
改善措施 Improvements
1
1. Update SPMP, adjust the original appearance inspection process 100 % detection PCB board and iron
shell gap work to measure the performance
2. Update the assignment guidance, and clearly require employees to use the ruler to detect the distance
between the Hall board.
Responsible person: Jiang Jincheng; completion time: 2023.4.26.
1、更新SPMP，将原先外观检验工序百分百检测 PCB板与铁壳间隙工序调整到马达空载测试性能前进行测量
2、更新作业指导书，明确要求员工使用卡尺检测霍尔板间距时，测量的位置，需要避开的测试点。
责任人：蒋金成；完成时间：2023.4.26.
Vietnam Rotong Electro-Mechanics Co., Ltd
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
03-2
改善措施 Improvements
1
2. Increase the inspection of Hall special equipment for incoming material inspection,
and spot check the status of PCB boards
Person in charge: Cai Wenming; completion date: May 20, 2023
2、来料检增加检查霍尔专用设备，抽检PCB板状态
责任人：才文明；完成时间：2023年5月20日
Vietnam Rotong Electro-Mechanics Co., Ltd
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
03-3
改善措施 Improvements
1
3. Adjust the motor performance testing machine of the production line. When the equipment is
found to be defective during the test, the motor on the measuring station must stop rotating and
cannot run, so as to avoid the situation where employees do not look at the test screen and see
that the motor can rotate and think it is a qualified product. .
Person in charge: Jing Linghong; Completion time: 2023.4.24
3.、调整产线马达性能测试机，设备在测试过程中发现不良时，测量工位上的马达要停止转动不
能运行，避免员工不看测试屏幕，看见马达能转动就认为是合格品的情况。
责任人：敬灵洪；完成时间：2023.4.24.
Stop testing if the
equipment is
found to be
defective设备发现
不良就停止测试
Vietnam Rotong Electro-Mechanics Co., Ltd
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
03-4
改善措施 Improvements
1
4.For the motor performance testing machine, replace the loud and loud alarm to
remind employees to identify defective products.
Person in charge: Jing Linghong; Completion time: 2023.4.26.
4、马达性能测试机，更换声音跟大的报警器，提醒员工能够识别不良品。
责任人：敬灵洪；完成时间：2023.4.26
Vietnam Rotong Electro-Mechanics Co., Ltd
Nhon Trach III Industrial Park, Nhon rach District, Dong
Nai Province
Thank you for watching
越南露通机电有限公司
Vietnam Rotong Electro-Mechanics Co., Ltd
编 制 ： 黄 美
日期：2023.4.26