TQM CONSULTANTS CO. LIMITED 
Achieved outstanding results through Comprehensive Process Reform
TQM provided comprehensive consulting services for Keetat Lighting
- Focused on Production Material Control, accelerated the production process and semi-finished product turnover, increased ￥13 million in working capital, saved the company’s ￥1.5 million in WIP every year and successfully reduced 44% of sluggish materials
- Changed the SMT workshop production model, shortened the entire production cycle from 14 days to 2 days, changed the island-style production layout due to the long ageing time, and shortened the assembly time from 7 days to 1 day
- Solve the product steady-state/burn-in test problem, optimize the filament firing process, reduce the defect rate from 3% to 0.4%, i.e. more than 85%
- Used JIT/VMI to improve warehouse and purchasing management, the inventory turnover rate has been increased from 7 revolutions per year to 14 revolutions per year!
Keetat Lighting Co., Ltd. is a leader in the solid-state lighting market and a well-known manufacturer of smart products and audio products. The products are sold all over the world and the annual turnover exceeds 100 million US dollars. To develop high-quality and creative products more effectively for customers is Keetat Lighting’s persistent pursuit of excellence! Keetat hired TQM to carry out a 16-month benefit reform project, which improved the entire manufacturing process and after-sales customer satisfaction.
| T | Product Aging Time | >120 min ➜ 60 min |
|---|---|---|
| Q | Burn-in Defect Rate | 3% ➜ 0.40% |
| M | Sluggish Material Storage | ￥14M ➜ ￥6M |
