www.sylvania.com Light is productive Lean strategies for industrial facilities
You ve improved your plant efficiency, now shed some light on modernization. North American manufacturing facilities are transforming their operations to stay competitive with foreign companies. Lean transformations are being implemented to improve throughput, reduce costs, reduce waste, and reduce errors. Transforming your electric lighting plays an important role in improving all aspects of the day-to-day operations of your facility. Lower your overhead costs Lighting installed at your facility as recently as 10 years ago should be upgraded to more efficient and longer life lighting options to lower your energy consumption and reduce lighting maintenance costs. Re-evaluate your lighting needs to achieve the best solution for the application. Save energy Energy savings up to 50-70% are possible with advanced lighting solutions. Tailoring a smart lighting controls strategy to operational needs can further reduce energy bills, resulting in dramatic reductions in Total Cost of Ownership (TCO) of a modern lighting system. 2
Industrial facilities Maintenance cost reduction Lighting system failures can disrupt operations and create safety issues for an industrial facility. Advanced lighting technologies can deliver up to 100,000 hours of worry-free service to maximize plant performance. Control systems can monitor and report usage and failures, further minimizing labor cost and downtime, and contributing to improved safety and security. Improved productivity Fewer errors and better accuracy by your workforce means increased throughput and a lower cost of doing business. Older lighting systems may no longer deliver adequate illumination. In addition, original lighting designs may not have been updated with changes in manufacturing processes and equipment. A thorough design audit can identify where improved lighting quality may be required within your plant. Sustainability Most companies today have a green initiative in place for waste reduction, recycling and reuse of materials. Modernizing your facility s lighting system is a visual way to show your commitment to environmental responsibility with newer, more environmentally preferable technology, and reduce your CO2 emissions. It can become a source of employee and community pride as part of your sustainability program. OSHA* recommends that employers use ANSI /IES RP-7-01 recommended practices as guidelines to determine sufficient lighting required to provide for the safety and health of employees in workplaces.1 Facility modernization The industrial segment is a very competitive landscape. Process standards and efficiency upgrades are critical to a lean operation. Many government agencies and utility companies offer rebate programs that can offset a portion of lighting improvements to ensure a safe environment that optimizes energy savings and plant performance. * Occupational Safety & Hazard Administration American National Standards Institute Illuminating Engineering Society 1 ANSI A11.1-1965, R1970, Practices of Industrial Lighting 3
Industrial facilities Lighting considerations Designing lighting for industrial facilities is an exercise in choosing illumination appropriate to the tasks performed in each area. Selecting lighting levels by application is critical to workplace efficiency and safety. The Illuminating Engineering Society (IES) recommends illumination requirements tailored to all types of manufacturing processes, tasks, and conditions. The lighting design should address visual comfort and safety considerations. Manufacturing and fabrication Profitability in an industrial facility depends on high operational efficiency in manufacturing processes where quality goods can be produced in a safe environment and defects can be eliminated quickly. Recommended illumination to support these activities can vary greatly depending on intricacy, process speed, contrast, level of automation, and cleanliness of the operation. Special attention should be given to ensure that lighting systems do not mask the motion of machinery that may cause injury. Assembly and inspection Assembly areas can require 5-8 times the amount of illumination than general areas. The configuration of work cells and specific task requirements will determine the overall needs of the lighting system. Task lighting at workstations offers the most design flexibility and optimal energy benefits, while allowing adjustments for personal comfort. The defect identification process will dictate whether inspection lighting needs to be more or less diffuse, come from a particular direction, and whether higher color rendering light sources are needed. Signage and wayfinding Reinforce and refresh your brand identity by refreshing or adding illuminated signage. Wayfinding provides visual cues for visitors, employees, and first responders. Special environments From environmental constraints such as temperature, humidity, vibration, and cleanliness requirements to process parameters such as chemical exposure, hazard requirements, and washdown procedures, many factors affect the selection of light sources and equipment that should be considered in determining what is best suited for a given area. Warehousing and logistics Storage and equipment configuration will determine the best luminaire photometric distribution for achieving uniform, glare-free illumination, particularly on vertical surfaces where reading case labels are critical for product and part identification. Use of occupancy sensors is recommended to optimize energy savings. Lighting should be flexible to highlight areas at times of high traffic and potential conflict, such as loading docks and fork truck drive lanes. Administration spaces Front office areas should not be overlooked for lighting upgrade opportunities. Recent advancements in lighting technologies and controls can realize energy cost reductions of 20% or more. Exterior areas Safety, security and maintenance concerns for your building perimeter and parking areas with older lighting systems can easily be addressed with longer life, better lighting options. Light trespass and sky glow should be considered to minimize environmental impact and maintain good community relations. 4
Industrial facilities SYLVANIA products and solutions Your blueprint for better lighting. 1 Manufacturing and Fabrication 2 Assembly and Inspection 3 Warehousing and Logistics 4 Administration Spaces 6 2 1 5 6 Exterior Areas Signage and Wayfinding 3 7 Special Environments 7 4 5 SYLVANIA product portfolio LED Lamps ULTRA PRO & ULTRA PRO HD LED PAR ULTRA LED PAR, R/BR, MR16 ULTRA LED A-line, B10, G25 ULTRA LED High Lumen SubstiTUBE IPS LED T8 LED Retrofit Systems & Kits ULTRA LED RT & ULTRA LED SE RT Downlight Kits SubstiTRONIC LED T8 Systems LEDVANCE 2X2 & 2X4 Retrofit LED Luminaires LEDVANCE Edge Lit Panel LEDVANCE Surface LEDVANCE Vapor Tight LEDVANCE High Bay LEDVANCE Wall Packs LEDVANCE Canopy Fluorescent Lamps & Ballasts OCTRON & OCTRON XL T8 PENTRON T5, T5 HO, T5 HO XL DULUX & DULUX XL CF SYLVANIA Mini Twist CFL OSRAM QUICKTRONIC Ballasts HID Lamps & Ballasts METALARC MH METALARC Pulse Start METALARC POWERBALL MH LUMALUX & LUMALUX XL HPS OSRAM QUICKTRONIC MH Incandescent/Halogen Lamps CAPSYLITE PAR TRU-AIM MR16 SYLVANIA R/BR, A-line SYLVANIA B10/B12, G25 5
Lighting solutions Developing the right solution for your facility Light quality All modern SYLVANIA lighting technologies are capable of delivering excellent quality light with color rendering index (CRI) values of 80 or better. For applications where distinguishing between subtle variations in color is critical for improved task performance, select higher CRI sources that are most stable over the life of the lighting system. High reliability Installing long life lighting systems means less downtime in an industrial facility. With OCTRON XP XL T8 fluorescent systems up to 84,000 hours average rated lamp life and LEDVANCE LED High bay luminaires up to 50,000 hours life, the burden on facility maintenance groups can be minimal. LED light sources have long life ratings, typically delivering 70% of initial lumen output (L 70 ) at up to 150,000 hours. Consider end-of-life characteristics of different lighting technologies when evaluating long life options. Systems designed with OSRAM QUICKTRONIC high efficiency electronic ballasts or high efficiency LED power supplies ensure most reliable and efficient performance. Illumination efficiency The efficiency of a lighting system depends on both the ability of the source to generate light and the luminaire delivering the light to the task. Today s source technologies have efficacies in the 85-110 lumens per watt (LPW) range. Selecting the appropriate luminaire for the application should pair the photometric distribution with the layout of the space. Care must be taken to address visual comfort and avoid glare. Sustainability Minimizing environmental impact and lowering greenhouse gas emissions is a priority. Through the development of long life, energy efficient SYLVANIA lighting products that minimize or eliminate the use of hazardous materials, such as mercury and lead, our portfolio strives to reduce waste going into landfills and into air via power generation emissions. Selecting luminaires that minimize light trespass and sky glow further lessens the impact on the environment. LED sources thrive in cold environments, but exhibit diminished performance in hot ambient conditions. High intensity discharge (HID) systems tend to show the least thermal sensitivity and therefore are excellent for unconditioned spaces where extreme ambient temperatures may occur. Use appropriately designed luminaires that protect system components in high dust or moisture conditions should they exist. Controllability A good lighting design should incorporate a discussion about controls strategy. While some lighting technologies, like fluorescent and LED, respond immediately with no warmup time or hot restrike concerns, HID systems have limitations in these areas. In industrial environments, a tremendous opportunity exists for step dimming applications, which may be accomplished with HID, fluorescent, and LED systems. Selection of high efficiency OSRAM QUICKTRONIC ballasts or high efficiency LED systems, sensors and switches should complement the controls strategy to optimize system life. Why install controls? A smart control strategy can tailor the lighting of a facility to the needs of the tasks performed in each space, and offer a tremendous opportunity to save energy and money. Light levels may be reduced or extinguished according to activity level, task requirements, operation schedules, or the presence of natural light. In some industrial applications, this can result in up to 50% energy savings. Energy management systems can be easily programmed and reconfigured as operations require. Many control systems have easy-to-use software offering consumption monitoring and reporting to notify you of outages or malfunctions, saving on maintenance costs and downtime. Life cycle cost and TCO A modern lighting system will (1) extend the useful life of your facility, (2) reduce energy consumption and waste, (3) improve the appearance of your space, and (4) add to your bottom line profitability and throughput. Environmental conditions Select lighting systems that best complement ambient conditions. Certain technologies can be more temperature sensitive than others, although proper luminaire design can often mitigate those characteristics. The output of fluorescent systems tends to decrease at very low or very high temperatures. 6
Lighting solutions Facility-wide analysis A thoughtful approach to developing a smart lighting concept marries energy saving products and the latest in lighting controls with the operation schedule, task requirements and an analysis of space utilization. As experts in lighting systems and applications, we can help your company customize a solution with the latest technologies to maintain or improve light quality, reduce energy consumption, and ultimately save you money. To capitalize on this opportunity, schedule a lighting design audit with your SYLVANIA representative. 7
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