INTRODUCTION:

Zener group of companies is the leading manufacturers of power conditioning

equipment’s. Its range includes online UPS systems, offline systems, servo
stabilizers, constant voltage transformers and other custom-built power supplies.
And the company gives employment to approx. 100 people in which mostly are
engineers from electronics background. However, the company’s service
department which oversees the complaints from customers, is getting a lot of
complaints regarding the failure across the different capacities o UPS system.
While a UPS is a system which is designed to provide a short-term power
supply to power demanding electronic equipment like computer,
telecommunication and so on. The UPS filters out small utility line fluctuations
and isolates equipment from large disturbances by internally disconnecting from
the utility line while supplying power from its internal batteries until the line
returns to safe values.
However, capacity contribute to majority of the complaints was unidentified
and hence failure analyses helps to identify the parameters on which special
attention should be given.

ANALYSIS
Here, company has utilized pareto chart and cause and effect chart to analyze
what are the failures and because of what customers are complaining about UPS
system. Company used pareto chart to find out where is the maximum failure
occurring.
1. PARETO CHART

 A Pareto Chart is a vertical bar chart in which the bars are arranged
in the descending order of their height starting from the left and
prioritize the problems or issues.

 How to create a pareto chart

- We must first make a table or list of problem classification.
- We must then tally the occurrences in each problem classification.
- After that, we must arrange problems/defects number from higher
to lower order.
- Then, we can construct the bar chart.
Company took these capacities to analyze through pareto chart what are the
failures.

Failure of UPS system

67

56
Number of failures

22

15
13
8 7
5 4 3
5 kVA 10 kVA 20 kVA 15 kVA 30 kVA 6 kVA 7.5 kVA 4.5 Kva 60 kVA 80 kVA

UPS capacities

Column2

they have seen that at capacities 5kVA and 10kVA number of failures are
higher than the other capacities of a system. So, they decided to focus on these
two capacities to improve them. They concluded that 10kVA is higher capacity
than 5kVA, so it will be beneficial to focus on 10kVA capacity of a system.
Now, they are trying to find why these failures are occurring, to find that they
developed cause and effect diagram.

2. CAUSE AND EFFECT DIAGRAM

 Cause and effect diagram are helpful in representing the relationship

between an effect and the potential or possible causes that influences it.
This is very much helpful when one wants to find out the solution to a
problem that could have a number of causes for it and when we are
interested in finding out the root cause for it.

 How to create cause and effect diagram

 - Decide which quality characteristic, outcome or effect you want to
examine (help of Pareto chart to find this)
- Backbone represents main straight line.
- Ribs represent categories.
- Medium size bones represent secondary causes.
- Small bones represent root causes.

Company has classified major causes into five categories to create cause and
effect diagram.
I. Input conditions
II. Materials
III. Process
IV. Customer infrastructure
V. Human resources

They have analyzed (pareto chart) that, under input conditions maximum
numbers of failures are occurring and fuse failures are highest among them.
Because of this they have concluded that ‘UPS system not working properly’ is
the main failure of the system.
They have done another pareto analysis to know clearly what the exact
problems are under “UPS system is not working’.
 Chart Title
15
14
13
12
11
10
Number of failuers

8 8
7
6 6
4 4 4
3 3
2 2 2 2 2 2

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in
Number of occurances

for 10kVA Series 3

From the pareto chart they have analyzed that fuse failure and loose connection
breakdowns the UPS system. So, these two failures can be taken into deeper
study for better outcome. For better understanding of fuse failure and loose
connection, they have made cause and effect diagram.
Fuse failure
They are divided into three main causes
- Input conditions
- Material selection
- Abuse
Transistor failure
They are divided into three main causes
- Functional problem
- Rating
- Abuse
CONCLUSION:

As determined from the Pareto analyses in which the system with capacity fails
the most and what are factors affecting it are obtained. So, to reduce the failures
it is advised that the system should have stabilize input current and power from
the main supply. As from this the service and quality of the systems will
increase and the company can have more profit margins which was earlier got
in to service and repair financial sector.