Optimization of Charger Connector Assembly Process Using a Semi-Automatic System to Enhance Accuracy and Reduce Defects

Abstract

The automotive sector necessitates superior charger connector assembly to enhance car performance and safety. The current PCBA to housing process involves manual assembly lacking a pressure regulated pressing fixture. The work instruction outlines the assembly procedures but lacks a defined insertion pressure requirement, potentially leading to inconsistent connection alignment and function failures during EOLT inspection. This study sought to enhance assembly precision and minimize flaws with a semi-automatic assembly method as a remedial measure. The methodology encompassed Fishbone analysis, EOLT verification, assessment of manual, back cover, and semi-automatic assembly techniques, as well as a comparative examination of production data pre- and post implementation. The semi-automatic method produced 10 acceptable units from 10 samples. Production statistics indicated that defective products diminished from 8.80% to 3%, however the success rate escalated from 90.20% to 97%. These findings demonstrate that regulated pressure enhanced assembly uniformity and diminished failure function.