Light Up the Visual FactoryLighting Solutions for Lean Manufacturing

June 18, 2012

Kathy EricksonTechnical Marketing Manager

Lighting & Indicators

OutlineI. 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

Section I

Banner LED Lighting Value Proposition

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 ProductivityVisual Task Performance

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Cornell Study at Xerox

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

• 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

Investigated 2 types of lighting in an office setting

Hedge A, Sims WR, Becker FD, “Lighting the Computerized Office,” presentation at the Human Factors Society, October 1989.

Mood and Alertness

Sorrowing old man ('At Eternity's Gate') by Vincent van Gogh (1890)

Bright light has been shown to:• Increase alertness• Improve cognitive function• Reduce fatigue

Reduction in Depressive SymptomsSubjects exposed to bright light (1000 lux) reduced depressive symptoms by 19%

Journal of American Medical AssociationRiemersma-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.

Health & Safety

Occupational Safety and Health Administration

Illumination Intensity (lux) Area of Operation

54 General construction area lighting.

54 Indoors: warehouses, corridors, hallways

54 Tunnels, shafts, general underground work areas

108

General construction plant and shops (e.g., batch plants, screening plants, mechanical and electrical equipment rooms, carpenter shops, rigging lofts and 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

OSHA

Ergonomic Work Environment

ErgonomicsThe study of designing equipment and devices that fit the human body, its movements, and its cognitive abilities.

Ergonomic WorkplacesCreate optimal working conditions within a work environment.

Appropriate Lighting:• Improves worker comfort• Increases job satisfaction levels

Improve Product Quality

Light up the GembaGemba (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

Lighting Level(lux)

Background Color

Minimum Defect Size

(µm)

Detection Frequency

5900 Grey 150 95%

2150-4000 Black/White 165 83%

European Pharmacopia Method 2.9.20

2000 – 3750 Luxvisual inspection of particulate contamination

Melchore JA, “Sound Practices for Consistent Human Visual Inspection,” AAPS PharmSciTech, March 2011, 12(1): 215–221.

$‐

$100 

$200 

$300 

$400 

$500 

$600 

$700 

$800 

0 10,000 20,000 30,000 40,000 50,000

Hours of Use

LEDFluorescentIncandescent

Reduce CostsLow Cost of Ownership – Reduced Maintenance

Model WLS28XW570XQT8 25W

Fluorescent60

WattPurchase price $209 $75 $15Energy cost per year $10 $25 $60 Replacement per year N/A 1 9Replacement bulb cost N/A $5 $1 Recycling cost N/A $10 N/AMaintenance cost N/A $10 $10 Cost per year $10 $50 $150

Reduce Waste

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

State-of-the-Art

Reduced Power BudgetTime Until BanIncandescent Ban is Global Movement

Time of year until ban takes effect: 1 – January 1; 2 – December 31; 3 – June 30 Sou

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Why Banner?

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

Industrial automation solutions experts

Section II

Lighting Terminology

Lumens vs Watts

Watt =

= LumenBrightness

Power

LumenWatt

= Efficacy

Lumens vs Lux

LumenTotal Output

360o

Luminous Flux(Unit = Lumens)

LuxLight on a Surface

Lumens/m2

Illuminance(Unit = Lux)

Common Lux Levels

Condition Lux

Clear daylight 10,000+

Overcast daylight 1,000

Hallway 100

Twilight 10

Full moon 0.1

CandelaIntensity of Light in a Particular Direction

Luminous IntensityUnit = Candela (Lumens/steridian)

rSA = r2 θ3D θ2D

r

S

θ3D = steridian ≡SAr2 θ2D = radian ≡

Sr

4π steridians = 1 sphere~12.57 steridians in a sphere

2π radians = 1 circle = 360o

1 radian ~ 57.32o

3D 2D

Luminance

Intensity of Light on a Surface (Plane)

r

r

2r

2r

3r

3r

• SI unit = candela/m2

• Solid angle of interest is typically the eye

• Used to characterize brightness of displays

• Sun at noon = 1.6×109 cd/m2

• >10,000 cd/m2 can cause visual discomfort

How Much Light Is Enough?IES Handbook has 571 pages on Lighting Applications

Lighting for Manufacturing – 79 pages

Application Recommended Lux

Ages 25-65

Recommended Lux

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

100% 25% 11% 6% 4% 3%

0 1 2 3 4 5 6

Inverse Square Law

Intensity =

0

200

400

600

800

1000

1200

0 1 2 3 4 5 6

Illum

inan

ce (Lux)

Distance (meters)

Illuminance vs. Distance

1r2

Rough Lighting Design

1. Measure area to be lit:

2. Determine target lux level:

3. Calculate lumen’s needed @ 1 meter:

4. Determine how far away the light must be:

5. Determine total lumens needed:

6. Determine beam angle of luminaire:

7. Convert to steridians

8. Multiply lumens by steridians

4’x2’ = 0.75m2

Detailed Assembly = 2000 lux

4’ = 1.22m

Lux Area = 2000 lux 0.75m2

= 1500 lumens

= 0.67 = 67% 1

1.222

1500 1.222 ≅ 2233 lumens

decrease in intensity =

θ = 11o

Ω = 2π(1-cos( ))11o beam angle = 0.0289Sr

θ2

2233 0.0289 = 64.5 lumens2233 3.14 = 7011 lumens

120o beam angle = 3.14Sr

Electromagnetic Spectrum

400nm 500nm 600nm 700nm

X-rays0.01–10nm

Gamma rays<0.01nm

UV10-400nm

Infrared740nm – 300µm

Radio waves<100,000km

0.00001nm 0.001nm 0.1nm 10nm 1µm 100µm 1cm 1m

Visible Light

Increasing Energy Increasing Wavelength

Color Temperature

North Light (Blue Sky)

Overcast Day

Noon Daylight

Early SunriseCandlelight

10,000 —

9,000 —

8,000 —

7,000 —

6,000 —

5,000 —

4,000 —

3,000 —

2,000 —

1,000 —

oK

temperatures • more contrast• better for visual tasks

temperatures more flattering to skin and clothing

Color Rendering IndexMeasure of a light sources ability to reproduce (render) colors

in comparison to a

Image courtesy of Adoniscik

• 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

Section III

Types of Lights

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 lossCharacteristics

• Inexpensive initial investment

• Color spectrum – continuous with more longer wavelengths

400 450 500 550 600 650 700

Wavelength (nm)

Inte

nsity

Problems• Short life ~ 750 – 5000 hrs

• Inefficient - 10% light; 90% heat

• Fragile

FluorescenceFundamentals• Low pressure ‘arc lamp’• Excitation of a gas (mercury vapor)• Arcing induced between electrodes• Electrons excite mercury which emits

photons in the UV range• Phosphor coating on tube used to convert

UV to visible light• Ballast – required to start electric discharge

and to limit operating current

300 350 400 450 500 550 600 650 700 750

Inte

nsity

Wavelength (nm)

Problems• Toxic mercury vapor• Required recycling• Fragile• Ballast inefficiencies• UV emissions• Shorter life ~ 10,000 – 30,000 hrs• Lifetime reduced with frequent on/off• Flicker (older models)

Characteristics• Inexpensive initial investment• Over 30 different color spectrums

High Intensity DischargeFundamentals• High pressure ‘arc lamp’• Excitation of a gas (mercury vapor + metal salts)• Arcing induced between tungsten electrodes• Ballast – required to start electric discharge and

to limit operating current• Common types: high pressure sodium, metal

halide, mercury vapor

300 400 500 600 700 800

Inte

nsity

Wavelength (nm)

Problems• Toxic mercury vapor• Required recycling• Fragile• Ballast inefficiencies• UV emissions (require UV blocking filters)• Shorter life ~ 10,000 – 30,000 hrs• Lifetime reduced with frequent on/off• Flicker (older models)

Characteristics• More efficient than

incandescent or fluorescent• Variety of color options

Light Emitting DiodesFundamentals• Solid-state Light (SSL): p-n diode• When electrons recombine with holes

they emit photons• Blue LED: GaN (gallium nitride) with

InGaN (indium gallium nitride) quantum wells

• White = Blue + Phosphor coating on inside of LED ‘package’

300 400 500 600 700 800

Inte

nsity

Wavelength (nm)

Characteristics• Lower energy consumption• Longer lifetimes (50,000 hours)• Improved robustness• Smaller size• Wide variety of color and

intensity options

Light Comparisons

Light Source Lamp Efficacy

LuminaireEfficacy

Incandescence (Std. Tungsten) 8-13 8-1318-32W Tube CFL 69-75 34-41LED 53 53

Light Source Avg. Life (hrs) Avg. Life 24hrs/day (years)

Avg. Life 12hrs/day (years)

Incandescence 1,000 0.11 0.22Tube Fluorescent 10,000 – 30,000 1.14 – 3.42 2.28 – 6.84LED 50,000 5.7 11.4

Brightness Brightness Brightness

Incandescent Lumens

Fluorescent T8 FixtureLumens

LED WLS28 Lumens

Wat

ts

100 W 1600

Wat

ts

32 W 1650

Wat

ts

18 1800 1130mm75 W 1100 25W 1250 15 1350 850mm60 W 800 19W 665 9 675 430mm40 W 450 15 W 490 6 450 285mm

Approximation of the number of lumens produced by typical incandescent and fluorescent luminaires (with ballasts). Actual values will vary by manufacturer and model numbers. Fluorescent fixture numbers assume a luminaire efficiency of 76 and a ballast factor of 75.

Section IV

Application Wins

Machine/Robotic Cell

Segment 1Dry

Segment 2H2O

Segment 3Wet Chemicals

Seg 4C1/Div2

S5Exp Prf

Low Performance High Performance

Spectrum of Automation Machines

Machine/Robotic Cell

Banner LEDs offer• Washdown safe• Shatterproof housings• IP69k ratings• Low DC voltage = PLC controllable• Small footprints• Magnetic mount and angle brackets

‘paper converting machine’ courtesy of Scott Behnke

Lights needed for• Safety• Operator Performance• Maintenance• Aesthetics

Industrial Enclosure/Electrical Panel

• Shatterproof housings• Low DC voltage draw• Small footprints

• Easy mount options• Cascade options• Variety of lumen options

Banner LEDs Offer

Maintenance Lighting

Banner LEDs offer• Small footprints• Magnetic mount • Low power consumption• Shatterproof housings

Work Station

Banner LEDs offer• Hazard free lighting• Long lifetimes• Low cost of ownership/low

maintenance costs• Variety of lumen options• Low power consumption• Cascade options

Mobile Applications

Banner LEDs offer• Robust housings• Low DC power draw• Variety of shapes and sizes• Variety of lumen options

Safety Illumination

Operator Illumination

Enclosure Illumination

Questions?

kerickson@bannerengineering.com