Edison Bulbs

Kee Tat Lighting Limited

Improve Time ►Quality ►Margin in a year
Industry: Lighting Industry
Service: LEAN 6 Sigma / BPI / -QA


TQM's Principal Consultant, Ir. Dr. Aaron TONG and Keetat's Director, Mr. ON

Kee Tat Lighting Limited is a well-known OEM/ODM/JDM manufacturer of home lighting, smart products and audio products, products are exported all over the world. Kee Tat invited TQM to carry out a year-long quality improvement project to improve the whole manufacturing process and aftersale customer satisfaction.


  • Analyzed the potential improvement area and time compression in the SMT process

  • Reviewed the performance appraisal system

  • Developed improvement program

  • Built up an incentive scheme to motivate staff to use the improved working process spontaneously


  • Reduce Production cycle from 14 days to 2 days

  • Lower the ageing failure rate from 3% to 0.4%, a total decrease of 87%

  • Enable Flexible Manufacturing and liquidized ¥ 13 million of WIP

  • Enable an annual saving of ¥1.5 million a year on semi-finished product scrap

  • Successfully reduces sluggish material by 44%

  • Increase inventory turnover from 7 rpm to 14 rpm, increased by 100%

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