Parts Quality Initiative

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Parts Quality Initiative (PQI) Ensures Equipment Reliability

In 2006, Exelon PowerLabs’ PQI program was founded to safeguard against downtime due to critical parts failure. Exelon PowerLabs uses historic model-specific failure data trends to identify which parts to PQI test.

PQI data and testing ensures defective parts are identified before installation, reducing downtime, labor and logistics costs, and yielding substantial warranty replacement savings.

PowerLabs is committed to working with manufacturers with high-failure rate parts to provide data and recommendations to solve the root cause of failure in manufacturing. For example, one vendor routinely had 40% failure rates on a tested part. PowerLabs identified the failure and worked with the vendor to modify the part, resulting in a failure rate of less than 3%.

How Does PQI Work?

Step 1: DATA

A PQI Membership includes a subscription to Exelon’s web-based OneLab portal, which reveals Exelon’s extensive PQI Analysis database comprised of proven PQI test plans for more than 2,000 models and historical failure trends on more than 75,000 parts.

Since 2006, Exelon has compiled data revealing trends in failure variables specific to part type, manufacturer and model number for safety and non-safety single point vulnerability applications.

Step 2: TEST

Send the hardware to one of Exelon PowerLabs’ sites for PQI critical characteristics testing. PQI ensures defective parts are identified before inventorying and installation, reducing downtime, labor and logistics costs. Testing newly procured parts before inventorying allows failed parts to be replaced for free within the warranty window, resulting in substantial cost savings. PowerLabs can also PQI test inventoried parts to verify older parts still perform their critical function.


PQI Drives Efficiencies

Top Failed Component Categories in the Last 5 Years by the Largest Number of Failed Samples

Exelon PowerLabs’ PQI program is a living program that is continually evolving as we test more parts each year.

Category Number of Samples Tested Number of Failed Samples Failure Rate
Relays 11,066 Tested 966 Failed 8.73% Failure Rate
Regulators 2,831 Tested 258 Failed 9.11% Failure Rate
Circuit Breakers 2,724 Tested 251 Failed 9.21% Failure Rate
Fuses 9,937 Tested 243 Failed 2.45% Failure Rate
Sensor Switches 3,149 Tested 197 Failed 6.26% Failure Rate

View Exelon PowerLabs PQI Case Studies

Failed Parts Testing Case Study
Failed Parts Testing Case Study
Failed Parts Testing Case Study

PQI Savings

The average parts failure rate across the PQI community is 7%. PQI provides two very valuable solutions:

  1. Testing critical components to ensure inventoried parts are fully functional.
  2. The cost savings of identifying deficient parts while still under warranty and before they are inventoried. This cost savings more than pays for the cost of implementing PQI year after year.

I would like to learn how PQI can ensure equipment reliability within my company.