A large number of defective products may not be due to the product itself.
In a production process that requires leak testing, a Leak Tester is an important tool used to check product quality before moving on to the next process or delivery to the customer.
However, in this case study, the factory suddenly found that a large number of products were detected as "failed", causing concern about potential product quality issues.
After further investigation, it was found that the products were not actually defective. This led to the suspicion that the cause might instead be a malfunctioning Leak Tester.
Problems encountered on-site
The factory encountered problems during leak testing, such as:
- A large number of products were deemed to have failed.
- Test results were inconsistent with the actual condition of the products.
- Products were not defective, but the leak tester might have had a problem.
- The measurement values of the Leak Tester were unstable.
- There was a risk of having to send the machine for repair.
- The cost of repairing the Leak Tester was relatively high.
These problems impacted production, quality control, and the cost of maintaining measuring instruments.
Cause Found: Contaminated compressed air may cause the Leak Tester to malfunction.
Upon investigation, it was found that the cause of the problem might be related to the quality of the compressed air used with the Leak Tester.
If the compressed air contains contaminants such as water, oil, oil mist, dust, or small particles, these impurities can accumulate inside the Differential Pressure Sensor, which contains important components like a diaphragm.
When contaminants accumulate inside the sensor, it can lead to unstable measurement values, cause the leak tester to malfunction, and result in non-defective products being incorrectly identified as defective.
Why is compressed air important for Leak Testers?
A Leak Tester is a high-precision measuring instrument, especially systems that use air pressure or differential pressure for leak detection.
If the compressed air used is not clean, it can affect the functioning of the sensors within the measuring instrument, leading to unstable readings or inaccuracies during inspection.
Therefore, the quality of compressed air is a crucial factor affecting the accuracy and stability of the Leak Tester.
Solution: Install a 3-in-1 Multi Dry Filter
To solve and prevent problems caused by contaminated compressed air, a 3-in-1 Multi Dry Filter was installed into the compressed air system used with the Leak Tester.
The 3-in-1 Multi Dry Filter is a compressed air filter that helps reduce contaminants in the air system, such as water, oil, oil mist, dust, and small particles, making the compressed air cleaner before it enters the measuring instrument.
By reducing contaminants in the compressed air, the Differential Pressure Sensor inside the Leak Tester will remain clean for longer, reducing the risk of the sensor malfunctioning.
Preventing problems is better than repairing the Leak Tester.
A Leak Tester is a high-precision measuring instrument, and repair costs can be high if the sensor or internal components are damaged.
Installing an appropriate compressed air filter is therefore a way to prevent problems before damage occurs, reduce the risk of inspection downtime, and help control maintenance costs in the long term.
Results after installation
After installing the 3-in-1 Multi Dry Filter, it was found that Leak Tester problems decreased, and measurement values became more stable.
The results included:
- Reduced Leak Tester malfunctions.
- More stable measurement values.
- Reduced risk of incorrect product rejection.
- Helped keep the Differential Pressure Sensor clean for longer.
- Reduced Leak Tester repair costs.
- Increased confidence in the quality inspection process.
Improving compressed air quality helped the leak detection system operate more accurately and stably.
Which factories are suitable for the 3-in-1 Multi Dry Filter?
The 3-in-1 Multi Dry Filter is suitable for factories experiencing these problems:
- Unstable Leak Tester measurements.
- Products deemed defective even though they are not.
- Malfunctioning leak testing equipment.
- Risk of contamination to the Differential Pressure Sensor.
- Compressed air contaminated with water, oil, or oil mist.
- Desire to reduce Leak Tester repair costs.
- Need to increase the accuracy of leak detection.
- Uncertainty about the quality of compressed air in the factory.
Conclusion
This case study shows that a large number of products detected as defective may not always be due to the product itself, but rather may be caused by a malfunctioning Leak Tester due to contaminated compressed air.
When compressed air contains water, oil, oil mist, dust, or small particles, these contaminants can accumulate inside the Differential Pressure Sensor, leading to unstable measurement values and affecting the accuracy of leak detection.
Therefore, installing a 3-in-1 Multi Dry Filter is one approach that helps reduce oil mist and contaminants in compressed air, prevents Leak Tester problems, reduces repair costs, and helps stabilize the quality inspection process.
If your factory is experiencing unstable Leak Tester measurements, malfunctioning leak testers, or high repair costs, checking the quality of compressed air and choosing an appropriate filter may help reduce problems and increase confidence in the production process.
For more product details, visit: https://thai.fakiki.com/pages/3-in-1-multi-dry-filter
Reference: https://www.maedauni.co.jp/casestudy/p969/
