Improvement of Product Quality Traceability Systems for High-Frequency High-Voltage Power Supply Manufacturers

Introduction
High-frequency high-voltage power supplies (with switching frequencies ≥50kHz) are widely used in medical imaging, semiconductor processing, and environmental protection. Their quality directly affects the performance of end products. A comprehensive quality traceability system is necessary to identify quality problems quickly, reduce recall costs, and improve customer trust.
System Improvement Measures
Full-life-cycle data collection is the foundation. For raw materials (e.g., high-frequency transformers, insulation films), each batch is assigned a unique QR code that records information such as supplier, production date, batch number, and inspection reports (including breakdown voltage, dielectric strength). During the production process, IoT sensors are installed on key equipment (e.g., winding machines, encapsulation machines) to collect real-time process parameters (e.g., winding tension, curing temperature, pressure) and link them to the product’s serial number. For finished products, all factory inspection data (e.g., output voltage stability, efficiency, EMI performance) are stored in a cloud database, accessible via the product’s serial number.
Blockchain technology is introduced to ensure data integrity. The traceability data (raw material information, production parameters, inspection results) are uploaded to a private blockchain network, where each data entry is encrypted and time-stamped. This prevents data tampering—any modification to the data will require the consensus of all nodes in the network, ensuring the authenticity and reliability of the traceability information.
Intelligent traceability analysis is realized through big data. The system uses machine learning algorithms to analyze the traceability data, identifying potential quality risks (e.g., a correlation between a specific batch of transformers and voltage fluctuation issues). When a quality problem occurs, the system can trace the affected products within 10 minutes (compared to 2–3 hours with traditional manual tracing) and generate a list of customers who need to be notified, minimizing the scope of product recalls.
Application Benefits
A high-frequency high-voltage power supply manufacturer that improved its traceability system reduced the time to locate quality problems by 90%, the recall rate by 45%, and customer complaints related to quality by 60%. Additionally, the system helped the manufacturer identify a defective batch of insulation films in advance, avoiding a potential loss of $200,000 in recall costs.