{"id":1156,"date":"2023-05-20T17:10:11","date_gmt":"2023-05-20T17:10:11","guid":{"rendered":"https:\/\/www.polarislight.com\/?p=1156"},"modified":"2023-06-05T16:28:45","modified_gmt":"2023-06-05T16:28:45","slug":"see-how-we-learned-from-apples-quality-assurance-to-produce-led-lights-with-zero-failure-rate","status":"publish","type":"post","link":"https:\/\/www.polarislight.com\/blogs\/news\/see-how-we-learned-from-apple-s-quality-assurance-to-produce-led-lights-with-zero-failure-rate","title":{"rendered":"See How We Learned from Apple\u2019s Quality Assurance to Produce LED Lights with ZERO Failure Rate"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"1156\" class=\"elementor elementor-1156\">\n\t\t\t\t\t\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-140fadc elementor-section-full_width elementor-section-height-default elementor-section-height-default\" data-id=\"140fadc\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-e98d2aa\" data-id=\"e98d2aa\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t\t\t<div class=\"elementor-element elementor-element-64e7275 elementor-widget elementor-widget-image\" data-id=\"64e7275\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<style>\/*! elementor - v3.13.2 - 11-05-2023 *\/\n.elementor-widget-image{text-align:center}.elementor-widget-image a{display:inline-block}.elementor-widget-image a img[src$=\".svg\"]{width:48px}.elementor-widget-image img{vertical-align:middle;display:inline-block}<\/style>\t\t\t\t\t\t\t\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"800\" height=\"392\" src=\"https:\/\/www.polarislight.com\/wp-content\/uploads\/2023\/05\/highbaylighting960x470-1647716121162-1.webp\" class=\"attachment-large size-large wp-image-1160\" alt=\"ZERO Failure Rate\" srcset=\"https:\/\/www.polarislight.com\/wp-content\/uploads\/2023\/05\/highbaylighting960x470-1647716121162-1.webp 960w, https:\/\/www.polarislight.com\/wp-content\/uploads\/2023\/05\/highbaylighting960x470-1647716121162-1-300x147.webp 300w, https:\/\/www.polarislight.com\/wp-content\/uploads\/2023\/05\/highbaylighting960x470-1647716121162-1-768x376.webp 768w\" sizes=\"(max-width: 800px) 100vw, 800px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-d92f96a elementor-section-full_width elementor-section-height-default elementor-section-height-default\" data-id=\"d92f96a\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-41547b7\" data-id=\"41547b7\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t\t\t<div class=\"elementor-element elementor-element-ef3819b elementor-widget__width-initial elementor-widget elementor-widget-heading\" data-id=\"ef3819b\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<style>\/*! elementor - v3.13.2 - 11-05-2023 *\/\n.elementor-heading-title{padding:0;margin:0;line-height:1}.elementor-widget-heading .elementor-heading-title[class*=elementor-size-]>a{color:inherit;font-size:inherit;line-height:inherit}.elementor-widget-heading .elementor-heading-title.elementor-size-small{font-size:15px}.elementor-widget-heading .elementor-heading-title.elementor-size-medium{font-size:19px}.elementor-widget-heading .elementor-heading-title.elementor-size-large{font-size:29px}.elementor-widget-heading .elementor-heading-title.elementor-size-xl{font-size:39px}.elementor-widget-heading .elementor-heading-title.elementor-size-xxl{font-size:59px}<\/style><h1 class=\"elementor-heading-title elementor-size-default\">How We Learned from Apple\u2019s Quality Assurance to Produce LED Lights with ZERO Failure Rate<\/h1>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-4170bc1 elementor-section-full_width elementor-section-height-default elementor-section-height-default\" data-id=\"4170bc1\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-10df6d0\" data-id=\"10df6d0\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t\t\t<div class=\"elementor-element elementor-element-6fab488 elementor-widget__width-initial elementor-widget elementor-widget-text-editor\" data-id=\"6fab488\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<style>\/*! elementor - v3.13.2 - 11-05-2023 *\/\n.elementor-widget-text-editor.elementor-drop-cap-view-stacked .elementor-drop-cap{background-color:#69727d;color:#fff}.elementor-widget-text-editor.elementor-drop-cap-view-framed .elementor-drop-cap{color:#69727d;border:3px solid;background-color:transparent}.elementor-widget-text-editor:not(.elementor-drop-cap-view-default) .elementor-drop-cap{margin-top:8px}.elementor-widget-text-editor:not(.elementor-drop-cap-view-default) .elementor-drop-cap-letter{width:1em;height:1em}.elementor-widget-text-editor .elementor-drop-cap{float:left;text-align:center;line-height:1;font-size:50px}.elementor-widget-text-editor .elementor-drop-cap-letter{display:inline-block}<\/style>\t\t\t\t<div class=\"sc-bQtKYq fbyRgD pf-12_\" data-section-id=\"pf-4ea5\" data-pf-type=\"Section\"><div class=\"sc-jHkVzv dyVEVs\"><div class=\"sc-hiCibw hHrFfF pf-13_ pf-r pf-r-eh\" data-pf-type=\"Row\"><div class=\"pf-c\"><div class=\"sc-hAcGzb bAQARH pf-14_\" data-pf-type=\"Column\"><p class=\"sc-fmBCVi laenLa pf-15_\" data-pf-type=\"Paragraph\"><span class=\"sc-jtXEFf kGfXVs pf-17_\" data-pf-type=\"Text\">Two years ago we decided to focus our entire R&amp;D spending on designing the most durable High Bays in the market. The decision behind our focus on durability came as feedback from our Installation team and Energy Analysis team. After providing 100\u2019s of large installations and calculations of Pay-back, we found that the cost of replacing failing High Bays far outweighs the cost of the fittings themselves. This led to a long R&amp;D effort:<\/span><\/p><p class=\"sc-fmBCVi laenLa pf-18_\" data-pf-type=\"Paragraph\"><span class=\"sc-jtXEFf kGfXVs pf-20_\" data-pf-type=\"Text\">Firstly, we had a team focusing on Quality Assurance. The team leader had been Heading up quality assurance for Apple and started to implement the same rigorous Quality assurance measures.<\/span><\/p><p class=\"sc-fmBCVi laenLa pf-21_\" data-pf-type=\"Paragraph\"><span class=\"sc-jtXEFf kGfXVs pf-23_\" data-pf-type=\"Text\">The lifespan of the fittings are primarily determined by the<a href=\"https:\/\/www.polarislight.com\/blogs\/news\/why-is-the-driver-the-most-important-part-in-led-light\" target=\"_self\">\u00a0LED Driver<\/a>\u00a0and the LED chips and most of our focuses were on these parts. First, we implemented rigorous testing of the Drivers before assembly in order to catch any small variations in the function of the drivers. Most producers rely on the driver manufacturers Quality Assurance, but we found that we could actually catch some minor variations that had been overlooked by the driver manufacturers. After production, we implemented a 48 hour testing of the fittings which includes driver testing, testing under running water and age testing.<\/span><\/p><p class=\"sc-fmBCVi laenLa pf-24_\" data-pf-type=\"Paragraph\"><span class=\"sc-jtXEFf kGfXVs pf-26_\" data-pf-type=\"Text\">Secondly, we increased the amount of led chips used on the high bays. Normally a 150w high bay will have 210 led chips and the LED chip manufacturers guarantee that 80% of these will function after 50,000 hours. We have increased this number of LED chips to 336 chips, giving less load on each chip, which means that we will still have 90% output after 50,000 hours (5 years) and 80% output after 100,000 hours (10 years).<\/span><\/p><\/div><\/div><\/div><\/div><\/div><div class=\"sc-bQtKYq fbyRgD pf-27_\" data-section-id=\"pf-2728\" data-pf-type=\"Section\"><div class=\"sc-jHkVzv dyVEVs\"><div class=\"sc-hiCibw hHrFfF pf-28_ pf-r pf-r-eh\" data-pf-type=\"Row\"><div class=\"pf-c\"><div class=\"sc-hAcGzb bAQARH pf-29_\" data-pf-type=\"Column\"><div class=\"sc-cLpAjG fYosfQ pf-30_\" data-pf-type=\"Youtube\">\u00a0<\/div><\/div><\/div><\/div><\/div><\/div>\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-4626726 elementor-section-full_width elementor-section-height-default elementor-section-height-default\" data-id=\"4626726\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-6d379ef\" data-id=\"6d379ef\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t\t\t<div class=\"elementor-element elementor-element-7c8ca27 elementor-widget elementor-widget-video\" data-id=\"7c8ca27\" data-element_type=\"widget\" data-settings=\"{&quot;youtube_url&quot;:&quot;https:\\\/\\\/www.youtube.com\\\/watch?v=Knnfz_h0sAk&quot;,&quot;video_type&quot;:&quot;youtube&quot;,&quot;controls&quot;:&quot;yes&quot;}\" data-widget_type=\"video.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t<style>\/*! elementor - v3.13.2 - 11-05-2023 *\/\n.elementor-widget-video .elementor-widget-container{overflow:hidden;transform:translateZ(0)}.elementor-widget-video .elementor-wrapper{aspect-ratio:var(--video-aspect-ratio)}.elementor-widget-video .elementor-wrapper iframe,.elementor-widget-video .elementor-wrapper video{height:100%;width:100%;display:flex;border:none;background-color:#000}@supports not (aspect-ratio:1\/1){.elementor-widget-video .elementor-wrapper{position:relative;overflow:hidden;height:0;padding-bottom:calc(100% \/ var(--video-aspect-ratio))}.elementor-widget-video .elementor-wrapper iframe,.elementor-widget-video .elementor-wrapper video{position:absolute;top:0;right:0;bottom:0;left:0}}.elementor-widget-video .elementor-open-inline .elementor-custom-embed-image-overlay{position:absolute;top:0;left:0;width:100%;height:100%;background-size:cover;background-position:50%}.elementor-widget-video .elementor-custom-embed-image-overlay{cursor:pointer;text-align:center}.elementor-widget-video .elementor-custom-embed-image-overlay:hover .elementor-custom-embed-play i{opacity:1}.elementor-widget-video .elementor-custom-embed-image-overlay img{display:block;width:100%}.elementor-widget-video .e-hosted-video .elementor-video{-o-object-fit:cover;object-fit:cover}.e-con-inner>.elementor-widget-video,.e-con>.elementor-widget-video{width:var(--container-widget-width);--flex-grow:var(--container-widget-flex-grow)}<\/style>\t\t<div class=\"elementor-wrapper elementor-open-inline\">\n\t\t\t<div class=\"elementor-video\"><\/div>\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-bafe5e2 elementor-section-full_width elementor-section-height-default elementor-section-height-default\" data-id=\"bafe5e2\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-51c2595\" data-id=\"51c2595\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t\t\t<div class=\"elementor-element elementor-element-dd241ca elementor-widget elementor-widget-text-editor\" data-id=\"dd241ca\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t<div class=\"sc-hiCibw hHrFfF pf-32_ pf-r pf-r-eh\" data-pf-type=\"Row\"><div class=\"pf-c\"><div class=\"sc-hAcGzb bAQARH pf-33_\" data-pf-type=\"Column\"><p class=\"sc-fmBCVi laenLa pf-34_\" data-pf-type=\"Paragraph\"><span class=\"sc-jtXEFf kGfXVs pf-36_\" data-pf-type=\"Text\">Secondly, we increased the amount of led chips used on the high bays. Normally a 150w high bay will have 210 led chips and the LED chip manufacturers guarantee that 80% of these will function after 50,000 hours. We have increased this number of LED chips to 336 chips, giving less load on each chip, which means that we will still have 90% output after 50,000 hours (5 years) and 80% output after 100,000 hours (10 years).<\/span><\/p><\/div><\/div><\/div><div class=\"sc-hiCibw hHrFfF pf-37_ pf-r pf-r-eh\" data-pf-type=\"Row\"><div class=\"pf-c\"><div class=\"sc-hAcGzb bAQARH pf-38_\" data-pf-type=\"Column\"><p class=\"sc-fmBCVi laenLa pf-39_\" data-pf-type=\"Paragraph\"><span class=\"sc-jtXEFf kGfXVs pf-41_\" data-pf-type=\"Text\">QA Rejection rate = +8%<br \/><br \/>\u00a0Increased Production cost = +11.5%<br \/><br \/>\u00a0Failure rate after installation = 0%<\/span><\/p><\/div><\/div><\/div><div class=\"sc-hiCibw hHrFfF pf-42_ pf-r pf-r-eh\" data-pf-type=\"Row\"><div class=\"pf-c\"><div class=\"sc-hAcGzb bAQARH pf-43_\" data-pf-type=\"Column\"><p class=\"sc-fmBCVi laenLa pf-44_\" data-pf-type=\"Paragraph\"><span class=\"sc-jtXEFf kGfXVs pf-46_\" data-pf-type=\"Text\">The sudden increased rejections by 8% put a strain on our operations and the use of more led chips led to a cost increase of 11.5%. However the end result is that we have had ZERO LED High Bays failing in the past two years, which saves our operations a lot of time and more than compensates for the increased production cost.<\/span><\/p><\/div><\/div><\/div>\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-5199174 elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"5199174\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-bfa7a9a\" data-id=\"bfa7a9a\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t\t\t<div class=\"elementor-element elementor-element-10debdc elementor-widget elementor-widget-image\" data-id=\"10debdc\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"480\" height=\"360\" src=\"https:\/\/www.polarislight.com\/wp-content\/uploads\/2023\/05\/hqdefault-1-1647783087274-1.webp\" class=\"attachment-large size-large wp-image-1161\" alt=\"ZERO Failure Rate\" srcset=\"https:\/\/www.polarislight.com\/wp-content\/uploads\/2023\/05\/hqdefault-1-1647783087274-1.webp 480w, https:\/\/www.polarislight.com\/wp-content\/uploads\/2023\/05\/hqdefault-1-1647783087274-1-300x225.webp 300w\" sizes=\"(max-width: 480px) 100vw, 480px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<section class=\"elementor-section elementor-top-section elementor-element elementor-element-8bd032e elementor-section-boxed elementor-section-height-default elementor-section-height-default\" data-id=\"8bd032e\" data-element_type=\"section\">\n\t\t\t\t\t\t<div class=\"elementor-container elementor-column-gap-default\">\n\t\t\t\t\t<div class=\"elementor-column elementor-col-100 elementor-top-column elementor-element elementor-element-34eb619\" data-id=\"34eb619\" data-element_type=\"column\">\n\t\t\t<div class=\"elementor-widget-wrap elementor-element-populated\">\n\t\t\t\t\t\t\t\t<div class=\"elementor-element elementor-element-a133703 elementor-align-center elementor-widget elementor-widget-button\" data-id=\"a133703\" data-element_type=\"widget\" data-widget_type=\"button.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<div class=\"elementor-button-wrapper\">\n\t\t\t<a href=\"https:\/\/wordpress-969684-3519179.cloudwaysapps.com\/blogs\/news\/\" class=\"elementor-button-link elementor-button elementor-size-sm\" role=\"button\">\n\t\t\t\t\t\t<span class=\"elementor-button-content-wrapper\">\n\t\t\t\t\t\t<span class=\"elementor-button-text\">BACK TO NEWS<\/span>\n\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"<p>How We Learned from Apple\u2019s Quality Assurance to Produce LED Lights with ZERO Failure Rate Two years ago we decided to focus our entire R&amp;D spending on designing the most durable High Bays in the market. The decision behind our focus on durability came as feedback from our Installation team and Energy Analysis team. After [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":1157,"comment_status":"open","ping_status":"open","sticky":false,"template":"elementor_header_footer","format":"standard","meta":{"nf_dc_page":"","footnotes":""},"categories":[26,27],"tags":[],"_links":{"self":[{"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/posts\/1156"}],"collection":[{"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/comments?post=1156"}],"version-history":[{"count":30,"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/posts\/1156\/revisions"}],"predecessor-version":[{"id":1948,"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/posts\/1156\/revisions\/1948"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/media\/1157"}],"wp:attachment":[{"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/media?parent=1156"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/categories?post=1156"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.polarislight.com\/wp-json\/wp\/v2\/tags?post=1156"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}