Case Study: Productive Lighting on the Shop Floor

January 25, 2024

Lighting can have a powerful impact on the human body. In addition to enhancing vision and reducing eyestrain, lighting stimulates hormones to decrease fatigue, increase alertness and elevate your mood. For these reasons, lighting also has a strong correlation with worker productivity. Studies have proven that proper lighting in production facilities can affect many aspects of a worker’s experience, including reduction of illness, accidents, and even absenteeism.

Regular lighting maintenance is essential to ensure that facilities receive the desired quantity and quality of light, as well as energy efficiency from their lighting systems. Beside increasing productivity, periodic maintenance can produce a range of benefits, including a brighter and cleaner workplace, as well as a higher level of security.

shop
MRS Industrial Improves Illumination

Founded in 1997, MRS Industrial specializes in all types of fabrication and installation work, design-build to specifications or from concept to completion. The Columbus, Ohio-based facility includes two buildings that are connected in the middle. The buildings are 80’ X 375’ and 80’ X 325’ with a 20’ ceiling height. Through its lighting management and maintenance program, regular lamp replacement of its T8, six-lamp, high-bay fixtures had become a popular choice to maximize lighting system effectiveness and control costs. However, the current lamps were no longer producing the appropriate lumens levels needed for productivity.

With its stringent and intricate manufacturing processes, MRS Industrial knew that the proper use of lighting could lessen the fatigue, production errors, and accidents—especially among nightshift workers or those on rotating shifts. With that the current lighting system no longer providing the needed illumination, the company determined it was time to update the lighting in the two buildings.

“We offer a wide range of mechanical services to many businesses nationwide. If you can dream it, we can build it,” said Scott Cosgrove, President at MRS Industrial. “So, we need to make sure our work force has proper lighting during manufacturing. Visual acuity for optimal lighting is extremely important to our productivity.”

Strategy to Maximize Lighting

To improve the illumination, MRS Industrial needed to determine the best relamping strategy that fit their facilities’ needs. MRS Industrial wanted to upgrade the current T8 fixtures with high efficiency LEDs. To determine the best products for the retrofit, MRS Industrial reached out to Bill Liberto, Regional Sales Manager for EarthTronics, Inc.  EarthTronics, Inc. manufacturers a wide range of energy saving long life LED lighting products for commercial and industrial applications.   Liberto met with Scott Cosgrove and reviewed the many options available to them to both reduce energy consumption and maintenance costs while increasing illumination levels at key points throughout MRS Industrial manufacturing processes.

“We assessed the wattage of lights over workstations, checked for burned-out bulbs, and even determined that the lighting fixtures were dusted and cleaned to evaluate our lighting needs,” said Cosgrove.

The team established three major criteria to replace the T8 fixtures. First, the new lighting system had to provide better efficiency in delivering lumens. Second, the team wanted to increase footcandles on the floor. Finally, the fixtures had to be more cost efficient.

As part of the process, the team worked with Bill Liberto at EarthTronics, who recommended a photometric fixture offering.  Liberto was put in touch with Doug Peterman, electrical owner of MCE, and salesman PJ White from Professional Electrical Product Company (PEPCO) Columbus, a premier electrical solutions distributor and packager, offering a full line of quality products, support personnel, and expert services.  Liberto worked in conjunction with PEPCO and Peterman to optimize the lighting fixtures photometrics. 

After a thorough investigation, the team specified 320-watt Linear Highbay LEDs from EarthTronics in the high-bay areas in the two facilities. Suitable for damp locations, the Linear Highbay LEDs feature a 5000K color temperature with a high 84 CRI to provide excellent visual acuity and illumination. They deliver excellent energy savings compared to similar linear fluorescent and HID fixtures. In fact, the lightweight, compact-designed fixtures deliver more than 50 percent energy savings and boast at a rated performance life of up to 100,000 hours.

“We learned that the Linear Highbay LED fixtures focus light more directly, creating strong and long-range illumination for use in manufacturing and warehouses,” said Cosgrove. “These high-bay LEDs would enhance workplace productivity by improving both visibility and safety.

For lower ceiling areas, the team specified 105-watt Linear Highbay LEDs also from EarthTronics. Both the 320- and 105-watt high-bay fixtures deliver 150 lumens per watt, operate on 120/277VAC, 50-60Hz, and feature an integral LED lens constructed from PMMA that provides even illumination across the face of the high bay. The fixtures also offer 0-10V dimming capability.

Results on the Shop Floor

MRS Industrial installed 75 of the 320-watt high bay LED fixtures in the high-bay areas, and another 15 of the 105-watt fixtures on lower ceiling areas.  The result of the new lighting system was dramatic on the shop floor. Light levels went from 12 footcandles to over 52 footcandles—more than quadrupling the light levels around key areas in the buildings.

More important, Cosgrove said, “The shop workers love how bright their work environment is now. We have noticed that the lighting has helped improve morale throughout the two buildings. In addition, we determined that the linear high bays fit nicely into our lighting management and maintenance program. Their next schedule relamping at 70 percent of the rated 100,000-hour lamp life will allow us to keep producing without disrupting productivity for a long time.”

Related Articles


Latest Articles

  • Video: LEDVANCE Lightpoint Learning Facility

    Video: LEDVANCE Lightpoint Learning Facility

    February 23, 2024 LIGHTPOINT Studio & Showroom, the brand-new corporate classroom training facility, located at their national customer service and sales center (NCSSC) in Westfield, IN. Go HERE for more information Read More…

  • How Effective Communication Reduces Plant Hazards

    How Effective Communication Reduces Plant Hazards

    February 23, 2024 By Rick Farrell, President, PlantTours In plant operations, the margin for error is notoriously slim. The smallest oversight, a single misinterpreted instruction, or an unnoticed alert can be the difference between smooth operations and catastrophic failures. While advanced technologies and protocols play an undeniable part in ensuring safety, the bedrock upon which… Read More…

  • A Guide To The Most Essential Hand Tools for Electricians

    A Guide To The Most Essential Hand Tools for Electricians

    February 22, 2024 By Jonard Tools It is currently a great time to be an electrician- however, you’ll need the right hand tools for the job. In this article Jonard Tools highlight the most essential hand tools for electrical work, as well as dive into the specifics of how they are utilized and why they’re… Read More…

  • New Research on Smart Home Technology and Market Trends

    New Research on Smart Home Technology and Market Trends

    February 22, 2024 AI-driven features in home energy management and security systems excite more than half of the current smart home users, concludes new research exploring the perceptions, preferences, and reservations of residential renters and owners regarding the adoption and usage of smart home technologies. However, the survey also highlights data privacy concerns and high… Read More…


Changing Scene

  • LEDVANCE Canada Welcomes Cristiano Konofal as National Account Manager

    LEDVANCE Canada Welcomes Cristiano Konofal as National Account Manager

    February 26, 2024 LEDVANCE Canada has introduced Cristiano Konofal as their National Account Manager. “I am thrilled to announce the return of Cristiano Konofal as a National Account Manager. Cristiano has extensive experience working with our customer base and has technical skills that will be an asset to our team. We look forward to seeing… Read More…

  • Government of Canada Invests in TDG Transit Design Group

    Government of Canada Invests in TDG Transit Design Group

    February 23, 2024 The Governemnt of Canada has announced a FedDev Ontario investment of over $1.6 million for TDG Transit Design Group, a manufacturer and designer of made-in-Canada, energy-efficient LED lighting systems for the global rail transit industry. Through this investment, TDG Transit Design Group will adopt new equipment at its newly expanded 10,000-square-foot facility… Read More…

  • Alberta to Invest in Apprenticeship Seats Through 2024 Budget

    Alberta to Invest in Apprenticeship Seats Through 2024 Budget

    February 23, 2024 Through their Budget 2024, Alberta’s government would invest an additional $24 million per year over the next three years to create 3,200 apprenticeship seats at 11 post-secondary institutions across the province. The new investment would bring the total funding through the Apprenticeship Learning Grant for the 2024-25 academic year to $78 million…. Read More…

  • PataBid and City Electric Supply Introduce Estimating Software Promotion

    PataBid and City Electric Supply Introduce Estimating Software Promotion

    February 23, 2024  City Electric Supply Corporation CA and PataBid have joined forces to offer our mutual customers an exclusive discount on Quantify electrical estimating software.  Sign up for a free trial and link your CES account to your PataBid Quantify account to unlock this special offer. If you’re not registered with CES yet, drop by… Read More…