Light Up the Visual Factory Lighting Solutions for Lean - PowerPoint PPT Presentation

Light Up the Visual Factory Lighting Solutions for Lean Manufacturing June 18, 2012 Kathy Erickson Technical Marketing Manager Lighting & Indicators

Outline I. Banner LED Lighting Value Proposition • Worker Productivity • Product Quality • Cost Reduction • Why Banner LED Lights? II. Lighting Terminology • Lumens, Lux & Candelas • Inverse Square Law • Color III. Types of Lights • Incandescence • Fluorescence • High Intensity Discharge • LED IV. Application Wins • Machine/robotic cell • Industrial enclosure/electrical panel • Workstations • Maintenance lighting • Mobile applications

Resources

Banner LED Lighting Value Proposition Section I

Visual Factory Visual Factory = Illumination + Indication Proper Industrial Lighting Can: • Reduce costs • Shorten cycle times • Improve product quality • Reduce power budget/ carbon footprint • Contribute to ergonomic work environment

Worker Productivity Visual Task Performance Figure 1: Mean performance scores for Weston’s Landolt ring tasks of different visual size and contrast, as a function of illuminance. Source: Dilaura DL, Houser KW, Mistrick RG, Steffy GR, The Lighting Handbook, Tenth Edition, New York, Illumination Engineering Society of North America, 2011. (IES Handbook)

Cornell Study at Xerox Investigated 2 types of lighting in an office setting • 1 in 4 workers reported loss of work time due to poor lighting • Up to 15 minutes per day → Over 1 hour per week → ~ 1 week lost per year → 3-5% loss in productivity Alan Hedge, Ph.D, Associate Professor William R. Sims Jr., Ph.D, Professor and Chairman Franklin D. Becker, Ph.D, Professor Department of Design and Environmental Analysis New York State College of Human Ecology Cornell University, Ithaca, New York Hedge A, Sims WR, Becker FD, “Lighting the Computerized Office,” presentation at the Human Factors Society, October 1989.

Mood and Alertness Bright light has been shown to: • Increase alertness • Improve cognitive function • Reduce fatigue Reduction in Depressive Symptoms Subjects exposed to bright light (1000 lux) reduced depressive symptoms by 19% Journal of American Medical Association Riemersma-van der Lek RF, Swaab DF, Twisk J, Hol EM, Hoogendijk WJG, Van Someren EJW, “Effect of Bright Light and Melatonin on Cognitive and Noncognitive Function in Elderly Residents of Group Care Facilities,” JAMA, June 2009, 299(22):2642-2655. Sorrowing old man ('At Eternity's Gate') by Vincent van Gogh (1890)

Health & Safety OSHA OSHA Occupational Safety and Health Administration Illumination Area of Operation Intensity (lux) 54 General construction area lighting. 54 Indoors: warehouses, corridors, hallways 54 Tunnels, shafts, general underground work areas General construction plant and shops (e.g., batch plants, screening plants, mechanical and electrical equipment rooms, carpenter shops, rigging lofts and 108 active store rooms, mess halls, and indoor toilets and workrooms. 323 First aid stations, infirmaries, and offices. OSHA guidelines from Code of Federal Regulations (CFR) 29, section 1926.56 presented in lux values

Ergonomic Work Environment Ergonomics The study of designing equipment and devices that fit the human body, its movements, and its cognitive abilities. Ergonomic Workplaces Create optimal working conditions within a work environment. Appropriate Lighting: • Improves worker comfort • Increases job satisfaction levels

Improve Product Quality Light up the Gemba Gemba (Japanese) ≡ ‘the real place’ • Core idea of lean manufacturing • Need problems to be visible • Then improvement actions can be implemented Need to See Problems

Visual Inspection More Light Enables Workers to See Smaller Defects Minimum Lighting Level Background Detection Defect Size Color Frequency (lux) (µm) 5900 Grey 150 95% 2150-4000 Black/White 165 83% Melchore JA, “ Sound Practices for Consistent Human Visual Inspection,” AAPS PharmSciTech, March 2011, 12(1): 215–221. European Pharmacopia Method 2.9.20 2000 – 3750 Lux visual inspection of particulate contamination

Reduce Costs Low Cost of Ownership – Reduced Maintenance T8 25W 60 $800 Model WLS28XW570XQ Fluorescent Watt Purchase price $209 $75 $15 Energy cost per year $10 $25 $60 $700 Replacement per year N/A 1 9 Replacement bulb cost N/A $5 $1 $600 Recycling cost N/A $10 N/A Maintenance cost N/A $10 $10 Cost per year $10 $50 $150 $500 $400 $300 $200 LED $100 Fluorescent Incandescent $ ‐ 0 10,000 20,000 30,000 40,000 50,000 Hours of Use

Reduce Waste The United States Environmental Protection Agency (US EPA) classifies fluorescent lamps as

State-of-the-Art

Reduced Power Budget Incandescent Ban is Global Movement Time Until Ban Source: McKinsey&Company Global Lighting Market Report, “Lighting the Way: Perspectives on the Global Lighting Market,” July 2011 Time of year until ban takes effect: 1 – January 1; 2 – December 31; 3 – June 30

Why Banner? Industrial automation solutions experts  Shatterproof, industrial lighting  Washdown safe, sealed IP69k models  High quality, aesthetically pleasing housings  Wide variety of colors, intensities and dimensions  Wide selection of mounting and electrical connections

Lighting Terminology Section II

Lumens vs Watts Brightness = Lumen Power Watt = Lumen = Efficacy Watt

Lumens vs Lux Lumen Lux Total Output Light on a Surface 360 o Lumens/m 2 Luminous Flux Illuminance (Unit = Lumens) (Unit = Lux)

Common Lux Levels Condition Lux Clear daylight 10,000+ Overcast daylight 1,000 Hallway 100 Twilight 10 Full moon 0.1

Candela Intensity of Light in a Particular Direction Luminous Intensity Unit = Candela (Lumens/steridian) S θ 2D SA = r 2 θ 3D r r 3D 2D θ 3D = steridian ≡ SA θ 2D = radian ≡ S r 2 r 4 π steridians = 1 sphere 2 π radians = 1 circle = 360 o ~12.57 steridians in a sphere 1 radian ~ 57.32 o

Luminance Intensity of Light on a Surface (Plane) • SI unit = candela/m 2 • Solid angle of interest is 3 r typically the eye 2 r r • Used to characterize r brightness of displays 2 r Sun at noon = 1.6×10 9 cd/m 2 3 r • • >10,000 cd/m 2 can cause visual discomfort

How Much Light Is Enough? IES Handbook has 571 pages on Lighting Applications Lighting for Manufacturing – 79 pages Application Recommended Recommended Lux Lux Ages 25-65 Ages 65+ Warehouse 100 200 Work area 150 300 General assembly 1,000 2000 Detailed assembly 2,000 4000 Fine inspection 5,000 10,000

Inverse Square Law 1 Intensity = r 2 100% 25% 11% 6% 4% 3% 0 1 2 3 4 5 6 Illuminance vs. Distance 1200 1000 Illuminance (Lux) 800 600 400 200 0 0 1 2 3 4 5 6 Distance (meters)

Rough Lighting Design 4’x2’ = 0.75m 2 1. Measure area to be lit: Detailed Assembly = 2000 lux 2. Determine target lux level: Lux Area = 2000 lux 0.75m 2 3. Calculate lumen’s needed @ 1 meter: = 1500 lumens 4. Determine how far away the light must be: 4’ = 1.22m 1 decrease in intensity = = 0.67 = 67% 1.22 2 1.22 2 ≅ 2233 lumens 1500 5. Determine total lumens needed: θ = 11 o 6. Determine beam angle of luminaire: θ 7. Convert to steridians Ω = 2 π (1-cos( )) 2 11 o beam angle = 0.0289Sr 120 o beam angle = 3.14Sr 8. Multiply lumens by steridians 2233 0.0289 = 64.5 lumens 2233 3.14 = 7011 lumens

Electromagnetic Spectrum Visible Light 400nm 500nm 600nm 700nm Gamma rays X-rays UV Infrared Radio waves <0.01nm 0.01–10nm 10-400nm 740nm – 300µm <100,000km 0.00001nm 0.001nm 0.1nm 10nm 1µm 100µm 1cm 1m Increasing Energy Increasing Wavelength

Color Temperature o K North Light (Blue Sky) 10,000 — 9,000 — temperatures • more contrast 8,000 — • better for visual tasks 7,000 — Overcast Day 6,000 — Noon Daylight 5,000 — temperatures 4,000 — more flattering to skin and clothing 3,000 — Early Sunrise 2,000 — Candlelight 1,000 —

Color Rendering Index Measure of a light sources ability to reproduce (render) colors in comparison to a • 1 to 100 scale • Higher is better • Below 5000K Comparison to ‘black body’ • Above 5000K comparison to daylight • Controversial • Some bulbs with better color rendering have lower CRI values Image courtesy of Adoniscik

Types of Lights Section III

Incandescence Fundamentals • Excitation of a solid • Current passed through high resistant wire • Filament (tungsten) – good compromise between lifetime and output • Bulb (glass) – provide airtight seal • Gas/vacuum – prevents oxidation of wire and convective heat loss Characteristics • Inexpensive initial investment • Color spectrum – continuous with more longer wavelengths Intensity Problems • Short life ~ 750 – 5000 hrs • Inefficient - 10% light; 90% heat 400 450 500 550 600 650 700 • Fragile Wavelength (nm)