Improving the Reliability of the LED Bulb Measurement System

Abstract

This study addresses deviations in optical parameters and inconsistencies in the light-quality control process for LED Bulb products at Center X of Corporation Y. It aims to identify the root causes of measurement errors and develop a standardized measurement system to improve the accuracy and reliability of product data prior to shipment. To achieve this objective, the study employed Pareto analysis to determine the most critical defect categories and measurement system analysis to isolate major sources of variation within the existing process. The results indicated that errors related to luminous flux and correlated color temperature accounted for 83.23% of total nonconformities, highlighting these factors as the dominant quality issues. In addition, the initial overall variation of the measurement system was 35.51%, exceeding the acceptable threshold specified in the AIAG Measurement Systems Analysis (MSA) guidelines and indicating a serious limitation in measurement capability. To address this issue, Poka-Yoke error-proofing was introduced through fixed-position markers on the lamp-holder mounting rod, along with the standardization of operating procedures. Following implementation, the overall variation index of the measurement system was reduced to below 10%. These findings demonstrate that standardizing measurement capability can establish a reliable data foundation for product quality assurance and support research and development in sustainable lighting technologies.