Modification of Manual HV Tester to Enhance Operator Convenience and Align with Product Requirements

PROBLEM STATEMENT

The manual HV tester with a 5kV manufacturer connector posed operational challenges, including inconvenience for operators and misalignment with the product’s voltage requirements.

PROBLEM ANALYSIS

The existing manufacturer connector design made it difficult for operators to use the HV tester efficiently. Additionally, the output voltage of 5kV exceeded the product’s requirement, resulting in inefficiencies and potential risks.

ROOT CAUSE

Lack of operator-friendly connector design in the existing HV tester.
The default output voltage of the tester (5kV) was not tailored to the specific needs of the product.

KAIZEN IDEA

Modify the HV tester by replacing the manufacturer connector with a banana connector for improved usability and reduce the locked output voltage to 1kV to meet product requirements.

COUNTER MEASURE

Replace the manufacturer connector with a banana connector across all manual HV testers.
Adjust the output voltage setting, locking it at 1kV.
Perform tests to ensure the modifications meet product specifications and operator usability standards.
Train operators on the updated design for efficient handling.

BENCHMARK

Zero operator complaints regarding connector usability.

Consistent output voltage locked at 1kV across all HV testers.

QUANTITATIVE

Enhanced operator convenience: Banana connectors are easier to handle, improving operational efficiency.
Better compliance with product requirements: The output voltage is now aligned with the product’s needs, reducing unnecessary risks.
Increased reliability: The modifications enhance usability and performance consistency in the HV testing process.