Tridonic is the world’s largest lighting, electronics and electrical products. They have strict requirements about the innovation and quality of the product, and they take the leading position in the industry of lighting control and drivers. In June 2018, they wanted to purchase some panel light. They had some requirements of quality. Firstly, the UGR of the light should be lower than 19. Secondly, the expansion rate of LGP should be smaller than the minimum standard of the market. Thirdly, it can withstand 5000-hour test at low and high temperatures. At that time, the UGR of other products in the market were up to 23. The expansion rate of LGP could not meet the strict requirements of Tridonic, and few products in this industry could withstand 5000-hour low-high temperature test. They tested samples from many large factories, but none of them met their requirements. Later they came to us by suggestion of our friend, and asked us to provide the sample.
I attached great importance to this client, so I decided to upgrade present production process in order to provide the qualified sample. Firstly, I spent more than 30,000 dollars to develop a device to upgrade the diffuser. In this way, we reduce the UGR less than 19. Secondly, we adopted hot-pressing technology to decrease the expansion rate of LGP. This is the newest technology in the lighting industry at that time. We were the first one to apply this technology on LGP. We realized the reason why television could adapt to all kinds of environment over the world was because its small expansion rate of LGP and it did adopted hot-pressing technology. So we introduced this technology into production of lighting, which completely solved the high expansion rate problem of LGP. After delivering those samples to Tridonic, they conducted 5000-hour test at low and high temperature. All of our products were up to their standards. They were very satisfied with our samples, and then they carried out a strict inspection on our factory. Finally, they placed an order to us.
In the first mass production, we met a big problem. The defective rate of product reached 27%. It was not acceptable. We had no choice but to improve production process to lower the defective rate. Through our analysis, we found the major reason. There were black spots on the prismatic plate which were caused by dust. The dust must be cleaned thoroughly so we improved another two production processes. Firstly, we started from raw material and clean the dust on prismatic plate. We attached a film to both sides of the raw plate to reduce the dust adhesion. Secondly, we removed the dust in the workshop. For this purpose, we developed a purely dust-free room system, installed with dust-cleaning equipment. When the product passed through, dust was cleaned. These two processes succeeded in reducing dust. By doing so, the defective rate of the product had lowered from 27% to 2% at once. A money-losing order became a profitable one.
When Tridonic received the goods, they were very happy. They said that few factories were willing to follow their requirements of products to make R&D investment and improve the production process. They paid great compliment to us and looked forward to more and deeper cooperation with us in the future.
