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

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 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

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 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.

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 OSHA

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

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 Lux

visual 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 10,000 20,000 30,000 40,000 50,000

Hours of Use

LED Fluorescent Incandescent

Reduce Costs

Low Cost of Ownership – Reduced Maintenance

Model WLS28XW570XQ T8 25W Fluorescent 60 Watt Purchase price $209 $75 $15 Energy cost per year $10 $25 $60 Replacement per year N/A 1 9 Replacement bulb cost N/A $5 $1 Recycling cost N/A $10 N/A Maintenance 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 Budget

Time Until Ban

Incandescent Ban is Global Movement

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

Source: McKinsey&Company Global Lighting Market Report, “Lighting the Way: Perspectives on the Global Lighting Market,” July 2011

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 = = Lumen Brightness Power Lumen Watt = Efficacy

Lumens vs Lux

Lumen

Total Output 360o Luminous Flux

(Unit = Lumens)

Lux

Light 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

Candela

Intensity of Light in a Particular Direction

Luminous Intensity

Unit = Candela (Lumens/steridian)

r SA = r2 θ3D θ2D r S θ3D = steridian ≡ SA r2 θ2D = radian ≡ S r

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%

1 2 3 4 5 6

Inverse Square Law

Intensity =

200 400 600 800 1000 1200 1 2 3 4 5 6

Illuminance (Lux) Distance (meters) Illuminance vs. Distance

1 r2

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

θ 2

2233 0.0289 = 64.5 lumens 2233 3.14 = 7011 lumens 120o beam angle = 3.14Sr

Electromagnetic Spectrum

400nm 500nm 600nm 700nm

X-rays 0.01–10nm Gamma rays <0.01nm UV 10-400nm Infrared 740nm – 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 Sunrise Candlelight 10,000 — 9,000 — 8,000 — 7,000 — 6,000 — 5,000 — 4,000 — 3,000 — 2,000 — 1,000 —

• K

temperatures

• more contrast
• better for visual tasks

temperatures more flattering to skin and clothing

Color Rendering Index

Measure 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 loss

Characteristics

• Inexpensive initial investment
• Color spectrum – continuous with more

longer wavelengths

400 450 500 550 600 650 700

Wavelength (nm) Intensity

Problems

• Short life ~ 750 – 5000 hrs
• Inefficient - 10% light; 90% heat
• Fragile

Fluorescence

Fundamentals

• 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

Intensity 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 Discharge

Fundamentals

• 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

Intensity 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 Diodes

Fundamentals

• 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

Intensity 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 Luminaire Efficacy Incandescence (Std. Tungsten) 8-13 8-13 18-32W Tube CFL 69-75 34-41 LED 53 53 Light Source

• Avg. Life (hrs)
• Avg. Life 24hrs/day

(years)

• Avg. Life 12hrs/day

(years) Incandescence 1,000 0.11 0.22 Tube Fluorescent 10,000 – 30,000 1.14 – 3.42 2.28 – 6.84 LED 50,000 5.7 11.4 Brightness Brightness Brightness Incandescent Lumens Fluorescent T8 Fixture Lumens LED WLS28 Lumens Watts 100 W 1600 Watts 32 W 1650 Watts 18 1800 1130mm 75 W 1100 25W 1250 15 1350 850mm 60 W 800 19W 665 9 675 430mm 40 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 1 Dry Segment 2 H2O Segment 3 Wet Chemicals

Seg 4

C1/Div2

S5

Exp 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