Delta 6, Sony - Lighting Research Center

DDEELLTTAAPortfolioDemonstration and Evaluation of Lighting Technologies and Applications • Lighting Research Center

Lighting Case Studies ▲ Volume1, Issue 6

Sony Disc ManufacturingSpringfield, Oregon

Type:Manufacturing Facility

Site Sponsor:Bonneville Power Administration

Host Utility:Springfield Utility Board

Sony Disc Manufacturing in Springfield,Oregon, opened in 1995 as a state-of-the-art manufacturing facility for digitaloptical discs. Operating 24 hours a day,this 324,800 square foot (30,856 squaremeter) facility sits on a 120-acre park-like site surrounded by forest. With 350employees, it currently produces asmany as 6.5 million discs a month.

Inside this building, a compact disc (CD)goes through the full production process.It begins with pre-mastering customermaterials (music or data, for example),then mastering a “mother” disc, thenproducing individual masters for replicat-ing the discs in quantity. Finally, CDs areprinted with artwork and packaged forshipping.

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Project Profile

Sony Disc Manufacturing in Springfield, Oregon

the Warehouse. Sealed clean room trof-fers and louvered direct/indirect pendantluminaires using T8 fluorescent lampsand high-performance electronic ballastsare used in the Staging, Replication andPrinting, Packaging, and Shipping andReceiving areas. All lighting circuits arecontrolled through a whole-buildingenergy management system (EMS). Thelighting power density in the industrialside of the facility is 1.04 W/ft2

(11.2W/m2).

This DELTA Portfolio evaluates spaceswithin the manufacturing facility exclu-sively and does not include the officespace, wellness center, dining areas, orother employee-centered areas of thebuilding.

The lighting in the manufacturing spaceswas designed to accommodate the manyvisual tasks involved in CD productionand to meet clean room standards forsome of the manufacturing processes. Innon-manufacturing spaces, the lightingprovides good task visibility with mini-mal glare, while accentuating the archi-tectural design and providing visualinterest. The design team, BoucherMouchka Larson, Architects and PAEConsulting Engineers, carefully coordi-nated architectural details with lightingand controls equipment.

The DELTA team evaluated several typesof industrial spaces. The lightingincludes glass reflector high-bay lumi-naires with 400-W metal halide lamps in

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Portfolio Lighting Case Studies

● Create work spaces with good task visibility and visual comfort for employees.

● Minimize energy use by using energy-efficient lamps, ballasts, luminaires, and controls.

● Create bright, visually stimulating spaces to help keep shift workers alert before sunrise.

● Keep initial cost of the lighting installation within budget.

● Qualify for utility-sponsored energy rebates.

Specific areas:● Staging and Replication and Printing areas: Use luminaires that conform to clean room standards. Provide uniform lighting

over floor area to accommodate frequent changes in equipment and its layout without shifting luminaires.

● Packaging: Provide evenly distributed workplane illuminance with minimal glare for a variety of packaging tasks.

● Warehouse: Provide uniform vertical illuminances on shelving in warehouse aisles to aid in reading labels on shelvedmaterials.

● Shipping and Receiving: Provide evenly distributed illuminance for easy viewing of labeled materials loaded into andunloaded from trucks.

● Lighting Objectives for the Industrial Areas

▲ Energy-efficient lamps and ballasts▲ High-efficiency clean room luminaires▲ Direct/indirect luminaires that help workspaces look bright▲ EMS that permits switching off lighting circuits in unoccupied areas

▲Lighting and Control Features

Clean Room LuminairesManufacturing techniques for delicate electronic media such as CDs require unusually clean environments called clean rooms. In thesespaces the concentration of airborne particles, temperature, and humidity are controlled to specific requirements. Workers wear specialclothing that helps prevent dust, dirt, and skin particles from entering the clean room.

Clean rooms are classified according to how many particles of a specific diameter are allowed in a cubic foot of air. For example, aClass 10,000 clean room cannot have more than 10,000 particles of 5 microns or larger per cubic foot.

Luminaires for clean rooms are specially designed to permit a smooth flow of air from air-filtering systems over their surfaces. Clean roomluminaires should have enclosed, gasketed, sealed designs to minimize dust, mold, and microscopic particles entering the room from theluminaire. They should also be designed to keep contaminants from the plenum from entering through holes for mounting hardware andelectrical feeds. Where magnetic ballasts are used, the magnetic flux can attract dust particles. This problem can be prevented by usingelectronic ballasts, which do not attract dust particles, or by mounting magnetic ballasts remotely, outside the clean room.

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Project SpecificationsThe principal light sources used in the Sonyfacility are T8 4’ (1.2 m) rapid-start lampswith a color rendering index (CRI) of 75 anda correlated color temperature (CCT) of 3500 K. The warehouse luminaires use400-W clear metal halide lamps and alsohave 250-W halogen lamps for instantaneouslight in emergencies. The adjustable loadingdock lights use 150-W PAR38/FL lamps.

All 4’ fluorescent lamps are operated on lowtotal harmonic distortion electronic ballastsfor energy efficiency and minimal interfer-ence with sophisticated electronic machin-ery. Metal halide lamps are operated withhigh power factor magnetic ballasts.

AA Pendant-mounted direct/indirectluminaire, 8’ (2.4 m) long, withmetal sides, two fluorescentlamps in cross section. Openupward, louvered downwardwith 45° cutoff. White-paintedfinish on housing and louver.Two-lamp electronic ballasts. Lamps: (2) F32T8/RE735

BB Recessed 2’ x 4’ fluorescent lumi-naire with three fluorescentlamps in cross section. Flush steeldoor with spring latches for easyaccess to lamp chamber. K12prismatic acrylic lens. Two-lampelectronic ballasts. Center lamps

of adjacent luminaires tandem-wired. Lamps: (3) F32T8/RE735

CC Recessed 2’ x 4’ fluorescent lumi-naire with three fluorescentlamps in cross section. Sealedand rated for Class 10,000 cleanrooms. K12 prismatic acryliclens. Two-lamp electronic bal-lasts. Center lamps of adjacentluminaires tandem-wired.Lamps: (3) F32T8/RE735

DD Extendable-arm “dock light” with swivel-adjustment head for directing light into trucks.

Lighting plan, Warehouse

N

0 8' 16' 32'

0 4m 8m 16m

Techniques

5

Mounted to wall adjacent toloading bays, 5’ (1.5 m) abovefloor. Yellow-painted finish.Lamp: 150PAR38/FL

EE Pendant-mounted enclosed andgasketed luminaire with 22” (0.5 m) diameter prismatic glassreflector and integral magneticballast. Luminaire produces 18%uplight, 82% downlight with narrow distribution optics, 0.8spacing criterion. 250-W halogenrestrike lamp provided in 12% ofluminaires. Lamp: M400/U (clear) metalhalide

WattageInput wattages for luminaires include ballast watts. Wattages are prescribedby the Oregon State Energy Code, an amended version of the UniformBuilding Code’s Chapter 53, “Energy Conservation.” The Code’s tables provide input wattage values (called luminaire power) for use in energy calculations for various combinations of lamps and ballasts.

T8 fluorescent lamps (electronic ballast)F32T8 (4’): 114 W per 4-lamp ballastF32T8 (4’): 93 W per 3-lamp ballastF32T8 (4’): 57 W per 2-lamp ballast

Incandescent lamps150PAR38/FL: 150 W

Metal halide lampsM400/U: 461 W


Lighting plan, Packaging, Replication and Printing, and Staging

Replication and PrintingArea In this 13,600 square foot (1263square meter) clean room, machinescalled solo-liners replicate CDs to exact-ing standards. Master discs called stam-pers imprint digital data onto blank CDs.The completed discs are then moved toa second bank of machines which silk-screen artwork onto them. Techniciansset up, adjust, and maintain the replica-tion machinery, and identify defectiveCDs. Printing operators enter codes toselect ink colors for the artwork, main-tain the autoroll machines, and brieflyinspect the artwork of every finished CDfor clarity and correct colors. Some CDsare inspected more thoroughly to catchmolding defects.

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Details

Replication area: clean room

Section A–A’. Printing/Replication at night in open area

Section B–B’. Printing/Replication at night in solo-liner area

96fc

98fc

105fc

157 cd/m2

112fc

11'196 cd/m2

126fc

12' 6"114fc

100fc

180 cd/m2

11' 48fc

62fc

46fc

67fc

80fc

69fc

59fc

12' 6"

63fc

73fc

0 4' 8' 16'

0 1m 2m 4m

117fc

115fc 124

fc127fc 121

fc95fc

124fc

127fc

125fc

7

Recessed 2’ x 4’ clean room luminaires(type CC) with three F32T8 lamps andelectronic ballasts provide ambient light.These luminaires are sealed to Class10,000 standards to prevent adding dust to the air or disrupting air flow oversurfaces in the room. Horizontal illumi-nance in the room depends on theamount of equipment in it: in a relativelyempty part of the room at night, floor illu-minance is between 95 and 135 footcan-dles (fc) (1020 to 1450 lux [lx]), butwhere the solo-liners are concentrated,the machinery itself blocks light and low-ers illuminance on the floor to 45 to 73 fc(490 to 790 lx).

Staging Area Technicians bringdefective discs from Replication into theStaging area to inspect and categorize thetype of error that caused the defect. Thetechnicians then identify the productionproblem so that they can make adjust-ments to the machinery. Visual tasks inthis area are extremely varied, difficult,and critical. They range from spotting tinyaberrations in the CD’s surface, to view-ing VDT screens and equipment monitors,to seeing through the large glass wall tomonitor activity on the production floor.

The Staging area is a long, narrow roomwith strict clean room requirements. Theelectric lighting is recessed 2’ x 4’ lumi-naires (type CC) with prismatic lensesand three F32T8 fluorescent lamps. Toaid in visual inspection, three 50-Whalogen gooseneck task lights have beeninstalled by management (and were notincluded in the energy calculations).

Early morning sunlight enters the Stagingarea through high clerestory windows inthe adjacent corridor for one to twohours a day most of the year. Unfortu-nately, the computer screens in this areaface the windows. Direct sunlight both-ers some technicians when it falls acrosstheir workspace or creates a bright,reflected image on their computerscreens. With daylight, vertical illumi-nances on screens are as high as 210 fc(2300 lx). Even when there is no directsunlight, the reflection of the clerestorywindows obscures computer screensand the view into Replication. At night,however, electric lighting adds no morethan 46 fc (490 lx) vertical illuminanceto screens, making them much morereadable.

Screen visibility varies according to thespecularity (shininess) of the screen, themaximum luminance (brightness) of thescreen, and the comparative luminanceof the characters against their back-ground (contrast). Highly specularscreens reflect far more of the distractingwindow brightness than screens withanti-reflection coatings. The windowreflection is also less noticeable on higher luminance screens.

Despite the reflections, technicians likebeing able to see the sky and tell whattime of day it is, even though they don’thave a view of the ground.


Staging

Section through Staging, day

Section through Staging, night

75 fc

167 fc153 fc

270 cd/m2194

cd/m2

7200 cd/m2 max3000 cd/m2 min


0 4' 8' 16'

0 1m 2m 4m

42 fc

95 fc82 fc

135 cd/m296

cd/m2



Details

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When daylight is not available, horizon-tal illuminances on both sides of theroom at the 3’-6” (1.1 m) countertop are82 to 95 fc (880 to 1030 lx), sufficientfor paper tasks anywhere in the Stagingarea. At midmorning on a typical partlycloudy day, daylight contributes up to anadditional 74 fc (800 lx) to these sur-faces.

When technicians make their first checkfor imperfections, they hold a CD slightlyabove eye level, using the reflection fromoverhead luminaires to reveal defects onthe shiny surface. They look for tinybumps, dimples, fibers, and particles ofdirt on the discs to determine if the repli-

cation machines are pro-ducing problems theymust correct. Severaltechnicians also use thehalogen task light to pro-duce a high-intensityreflection for a closercheck. Technicians reportthat neither the overheadlighting nor the task light-ing is well-suited to theirinspection tasks. TheDELTA team observedthat the task of detectinga variety of extremelysmall, low-contrast detailsrequires a variety of light-ing conditions. A dedicat-ed viewing booth wouldhelp make these flawsmore visible. (See LessonsLearned.)

Packaging AreaTasks in this area includeinserting CDs and paperliner notes into clearplastic cases, wrappingindividual cases in cello-phane, boxing the cases, and preparingthem for shipping. Much of the work ishighly automated, but 18 employees pershift visually inspect, adjust, and stockthe machinery.

The room is lighted entirely with three-lamp T8 recessed 2’ x 4’ lensed troffers(type BB) on 8’ x 8’ (2.4 x 2.4 m) cen-ters. High-frequency electronic ballastseliminate flicker so that moving machin-ery does not appear to stop or changespeed. The room has no windows.Although the lighting layout is very simi-lar to that in the adjacent Replicationand Printing area, the machinery isshorter in height and spaced farther

apart. As a result, the machinery blocksless of the light and the illuminance onhorizontal task surfaces remains fairlyhigh (108 to 115 fc [1160 to 1240 lx]).

Warehouse The warehouse spacehas 35’ (11 m) ceilings. It provides stor-age for manufacturing materials as wellas finished products. Two to fouremployees on each shift track inventorystorage and retrieval. Their desks arelocated in the warehouse, and they per-form both paperwork and computerscreen visual tasks. Forklift operatorsmoving materials on pallets need to readlabels quickly on both pallets and thevertical shelving members.Warehouse

Perspective of Warehouse

Staging Area (continued)

16 fc

15 fc

29 fc

17cd/m2 ceilingbetween luminaires

80.6cd/m2 ceilingabove luminaires

34’26 fc

12 fc

6 fc

4 fc

4 fc

3 fc

4 fc

7 fc

9 fc

10fc

3fc

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Glass reflector luminaires (type EE) with400-W clear metal halide lamps arependant-mounted near the bottom chordof the ceiling trusses. The luminaires arespaced on 20’ x 20’ (6.1 x 6.1 m) cen-ters. To avoid most of the glare and visu-al comfort issues associated with high-bay industrial lighting, the design teamspecified a white-painted ceiling andluminaires which direct 18% of theirlight upward. The luminance of the lumi-naire can be 22,000 cd/m2 or higher,and when contrasted against the whiteceiling, the sensation of glare is reduced,even though the contrast ratios do notchange very much. The bounced lightfrom the ceiling helps make light levelson the floor more uniform and also soft-ens shadows. Brightness on the ceilingappears fairly uniform, ranging from 17 cd/m2 to 82 cd/m2.

Four high-bay storage shelves are cur-rently in use, creating one full-heightaisle. The lighting has been coordinatedwith the shelf layout so that luminairesare centered directly above the 6’ (1.8 m)aisle. Vertical illuminances are relativelyuniform (less than 8 to 1 maximum tominimum) over the height of the shelves,making it easy for forklift operators to seethe package labels on the lower shelves.Illuminances on the floor of the aisle are15 to 21 fc (160 to 230 lx). In areas ofthe warehouse without tall shelving, theyrange from 32 to 37 fc (340 to 398 lx).

Shipping and ReceivingIn this area, workers retrieve an order offinished CDs from the warehouse,assemble it into boxes or pallets, andload it onto trucks through one of 12loading bays. Raw materials for manu-facturing are also received here. Visualtasks include reading package labels,filling out paperwork for dispatching,

Section through Shipping and Receiving

using computers to track orders, andloading materials in and out of trucks.

The ceiling height is 20’ (6.1 m). Eco-nomical T8 fluorescent direct/indirectpendants (type AA) are suspended 16’(4.9 m) above the floor in rows 10’ (3 m)on center. Light from the luminairesreflects off white-painted ceiling, trusses,and walls to produce very uniform illu-minances. Floor illuminances range from31 fc (330 lx) near the loading doors to43 fc (460 lx) in the center of the space.The luminaires emit much of their lightupward, and the ceiling brightness creat-ed by the uplight helps make the spaceappear large and bright.Ceiling luminances of 54to 96 cd/m2 help reducethe contrast between theluminaires and surround-ing ceiling. The lumi-naires have opaquemetal sides and down-light louvers with a 45°cutoff angle, dramatical-ly reducing the sensationof glare.

Swivel-head dock lights(type DD) with incandes-

cent PAR lamps are wall-mounted at eachloading bay to aim light into truck cavi-ties. The extendable arm projects lightinto the truck, which illuminates the areawhere the worker is headed. However, assoon as the worker walks into the beamof light, his or her body shadows the taskarea. Workers also complain of “extremeglare” once they turn around becausethey are now facing a high-candlepowerlight source that is very close to their lineof sight. As a result, workers in the Ship-ping and Receiving area report that thelighting for loading and unloading trucksis inadequate and uncomfortable. (SeeLessons Learned.)


Shipping and Receiving

26 fc 42 fc 37 fc 38 fc 38 fc 41 fc 23 fc

43cd/m2

95 cd/m2 aboverows of luminaires54 cd/m2 betweenrows of luminaires 16'

0 4' 8' 16'

0 1m 2m 4m

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and times of year. The building’s mechanicalsystem, which uses an economizer cycle inthis mild climate, was designed so that thelighting loads have little effect on HVACoperating costs. As a result, DELTA did notcalculate energy savings from reduced use.

According to the United States EnvironmentalProtection Agency’s (EPA) estimates on thereduction of emissions of harmful substancesinto the atmosphere for reductions in energyuse, the energy saved from lighting in theindustrial areas results in 2180 fewer tons ofCO2, 19 fewer tons of SO2, and 8 fewer tonsof NOX compounds emitted from powerplants per year.

The initial cost of the lighting equipment forthe whole building was $150,000 higherthan a more conventional design. However,the Springfield Utility Board and the powerdistributor, Bonneville Power Administration,compensated Sony for much of the differencewith a rebate of $102,000 to help defrayfuture energy generation costs in the PacificNorthwest.

Staff Response The DELTA teamsurveyed employees in several of the facility’smanufacturing areas to find out about theirimpressions and experiences with the light-ing. DELTA wanted to know about task visi-bility, visual comfort, problems employees

noticed with the lighting or windows, andoverall satisfaction with the lighting.Employees from several shifts completed sur-veys in each of the areas DELTA evaluated. Inaddition to rating their agreement with aseries of statements about the lighting, theychecked lighting problems they perceivedfrom a list. In areas with significant daylightcontributions, such as the Staging area, they

Building Areas and Lighting Power DensitiesSpace Total Total ASHRAE/IES Oregon State In-use LPD

area (ft2) connected LPD Allowed LPD Allowed LPD during dayStaging & Replication 15,502 1.87 — — —Packaging 23,491 1.64Shipping & Receiving 11,682 0.97 — — —Warehouse 57,358 1.14 __ __ __

Other Industrial Areas 119,088 0.77 — — —

Total Industrial Area 227,121 1.04 2.5 NA* 1.04Administrative Area 97,679 1.13 1.57** 1.2 0.95

Grand Total for Building 324,800 1.07 — — 1.01

*Oregon State Code excludes manufacturing from lighting energy use requirements. **From ASHRAE/EIES 90.1 1989 Table 6.5 ULPA for offices of 50,000–250,000 ft2

they can switch off lighting in areas that arenot in use. (The EMS is used extensively inoffice and other support spaces.) However,manufacturing operations run continuously,so lights are rarely off. The following tablesummarizes the lighting power density in theindustrial areas, compared to ASHRAE/IESenergy standards and the Oregon State Energy Code.

Environmental and Economic Analyses The lighting design features provided signifi-cant energy savings for Sony Disc Manufac-turing. DELTA compared the annual energycost for the industrial side of the buildingwith the annual energy cost for a facilityusing 2.5 W/ft2, the maximum whole-buildingLPD allowed by ASHRAE/IES 90.1 1989. Forthis comparison, DELTA assumed all lightsare in operation continuously.

The annual cost savings for lighting is$82,500 per year, assuming a $4.80/kWdemand charge and a standard industrialenergy rate for Springfield customers thataverages about $.026/kWh for a load ofSony’s size. The average energy rate isweighted for all quantities used, times of day,

Energy Impact DELTA calculatedlighting power densities (LPDs) for both theindustrial and the administrative parts of theSony facility. The total connected LPD in theevaluated industrial spaces is 1.34 W/ft2 (14.4W/m2). The in-use LPD is the same, becauseall lights are on 24 hours a day. Other spacesin the manufacturing side of the facilityinclude equipment maintenance areas, corri-dors, mechanical and electrical spaces, engi-neering and controls offices, and pre-master-ing rooms. When these spaces are includedin the calculation, the industrial facility’s totalLPD is 1.04 W/ft2 (11.2 W/m2). These LPDscompare very favorably with the ASHRAE/IES90.1 1989 whole-building unit lightingpower allowance (ULPA) of 2.5 W/ft2. TheOregon State Energy Code provides equip-ment wattages for lighting density calcula-tions, which DELTA used instead of manufac-turer’s input wattage data. (Although the Ore-gon State Energy Code governs the energyuse in this facility, the code specificallyexcludes manufacturing spaces from lightingpower density limits.)

Controls The EMS allows Sony’s facil-ities managers to control all lighting circuitsin the building from a central point so that

“I’ve screen-printed for several years andthis is one of the best lighting conditionsI’ve worked in.”

–Printing operator

ProjectEvaluation

11

were asked to rate the lighting for both dayand night.

About 70% of the employees in the manufac-turing areas approved of the electric lighting.Both midnight to noon (A.M.) and noon tomidnight (P.M.) shift workers in all areas likedthe lighting and found it comfortable. Howev-er, technicians who perform exacting visualtasks found the lighting less than satisfactory.

Staging More than a third of techniciansin the Staging area in A.M. and P.M. shiftsreported that the lighting did not enable themto see everything they needed to see clearlyand quickly. They said they wanted betterlighting to help them with their inspectiontasks. The A.M. workers were less satisfiedthan the P.M. workers. The reason, they com-mented, was that the early morning daylightfrom clerestory windows created reflectedglare on computer screens and glass walls.A.M. workers also complained about directglare from the morning sun (57%) and thestrong shadows cast by the sun (29%).

Replication and Printing More thanhalf of the technicians in the Replication andPrinting area also reported that they couldnot see everything they needed to see quick-ly and clearly. Among A.M. workers in theReplication area, 30% reported a problemwith glare from sunlight and patchy lighting;19% of all workers complained of strongshadows. The Printing area techniciansreported that the general lighting was notdesigned for their specific visual tasks, such

as identifying problems inside the printingmachinery where artwork is stamped ontothe silk-screen master, visual inspection of thecompleted printed discs, and color matchingto ensure that printed colors match artworkcolors.

Packaging In Packaging, visual tasks are less demanding than in the Staging, Repli-cation, or Printing areas. Employees in thisarea were generally satisfied with the lighting,found it comfortable, and reported that theycould see quickly and clearly. The Packagingarea has no windows, so employees did notcomplain about daylighting, but some didreport glare from reflections of the overheadlighting in shiny packaging materials such asshrink-wrap plastic. Others complained ofannoying glare from light refracted throughthe edges of their safety glasses, or from elec-tric lighting. Too much light was a problemfor 15% of these employees.

Warehouse In the Warehouse area,workers were quite satisfied. Light levelswere sufficient for driving and using a forklift.The metal halide lamps used in this areadrew no complaints about flicker or color,although workers reported glare when they

needed to see the top of the warehouseshelves while standing on the aisle floor.From this viewing angle, it is hard to avoidseeing the metal halide lamp directly.

Shipping and Receiving Someproblems surfaced in Shipping and Receiv-ing, particularly at the loading docks. Whenemployees drive forklifts out of the dark inte-riors of trucks, they report glare or even“blinding” from the incandescent PAR-lamptask lights that are arm-mounted at the edgeof the loading dock. Employees working atloading or unloading trucks find that theirown strong shadows interfere with their abili-ty to see objects and labels at the far end ofthe truck. (See Lessons Learned.)

Maintenance and Product PerformanceSony’s facilities managers have reported an above-average maintenance performancefor the lighting design in the 18 months thefacility has been open. No frequent lampburnouts requiring continued maintenanceand very few ballast failures have occurred.Managers are very pleased that the energy-efficient lighting design has kept energy useto a minimum.

LIGHTING SURVEY—Percentages of People Who Agree*:Replication Shipping && Printing Staging Packaging Warehouse Receiving

I like the lighting of this area 71 77 66 70 67The lighting is comfortable 78 73 61 60 67The lighting helps me see clearly/quickly 44 63 81 60 67Having daylight is important — 65 — — —

Percentages of people who checked as a lighting problem:Too little light 17 0 7 20 16Too much light 10 12 15 0 0Glare from electric lighting 15 6 30 30 16Glare from sunlight 17 25 3 10 0Shadows 19 19 5 20 16Patchy lighting 24 6 5 10 0Flicker 0 0 8 0 0Poor light color 5 0 12 0 0Reflected patterns of light 5 12 3 10 16

*Responses from A.M. and P.M. workers are combined.


“This facility is a lot lower maintenancethan other manufacturing buildings.”

–Manager of Facilities Engineering

“[In Printing] light is not directed toaccomplish specific tasks, such as seeinginside autoroll print heads, or visualinspection of printed discs, or to verifymatching ink to the color chart.”

–Technician, Replication and Printing

Copyright © 1997, Rensselaer Polytechnic Institute. All rights reserved. Neither the entire publication nor any of the information contained herein may be duplicated or excerpted in any way in any otherpublication, database, or other medium and may not be reproduced without express written permission of Rensselaer Polytechnic Institute. Making copies of all or part of this publication for any purpose other

than for undistributed personal use is a violation of United States copyright law.

ISSN 1075-3966 Printed on recycled paper

For publications ordering information contact:Lighting Research Center, Rensselaer Polytechnic Institute, Troy, New York 12180-3590 • FAX (518) 276-2999

Phone: (518) 276-8716 • e-mail: [email protected] Wide Web: http://www.lrc.rpi.edu


DELTA Portfolio Lighting Case Studies

Volume 1, Issue 6Sony Disc Manufacturing, Springfield, ORSite Sponsors:

Bonneville Power AdministrationDELTA Members

Host Utility: Springfield Utility Board

April 1997

Program Director: Naomi MillerReviewers: Russell P. Leslie, Mark S. ReaProject Coordinator: Linda SanfordEvaluation Team Leader: Peter BoyceEvaluation Team: Russell P. Leslie,

Kathryn Conway, Craig CirannyPublication Manager: Judith BlockEditor: Claudia Hunter

CREDITSSony Contact: Monica ShovlinBonneville Power Administration Contact:

Craig CirannyBuilding Owner: Sony Disc ManufacturingArchitect: Boucher Mouchka Larson,

Architects, Portland, ORElectrical Engineer: PAE Consulting

Engineers, Portland, ORLighting Design: PAE Consulting Engineers;

Naomi Miller, IALDElectrical Contractor: L.H. Morris

Electric, Inc.General Contractor: Baugh Construction,

Springfield, OR

Luminaire Manufacturers:AA,BB—Lithonia; CC, DD—Guth; EE—Holophane

Ballasts: Holophane and AdvanceEnergy Management System: Lithonia

DELTA Portfolio Graphic Designand Production: JSG Communications, Inc.

Photographers: Steve Cridland, all photos except Staging and Replication areas; Todd Kornfeld, Staging and Replication areas;Kevin Ellsworth, exterior

Lessons Learned• Choosing the right computer screen

can solve VDT lighting problems. Thesurface characteristics of a computerscreen affect its visibility. A screen withhigh luminance (brightness) and a goodanti-reflection coating can reducereflected glare to such an extent thatalmost any electric lighting system willwork well. It is only when poor qualityscreens are used that design of thelighted environment is critical.

• Task visibility is not always improvedwith more light. In the case of inspect-ing CDs for irregularities, high ambientlight levels did not improve visibility. Itis often more economical in terms ofequipment and energy to design a spe-cial viewing booth which can enhancethe visibility of surface or substrateflaws through side lighting, a selectivelight spectrum, specular reflections,diffuse lighting, or other visual inspec-tion techniques. This viewing boothshould be specifically designed for theapplication and specific features thattechnicians must detect.

• Windows can reduce visibility. Reflec-tions of bright windows can seriouslyinterfere with visibility through interiorpanels of glass or with visual tasks per-formed on computer screens. Althoughemployees enjoy the ability to see out-doors, glare-control devices such asblinds or shades should be installed toblock the offending light at the time ofday or year when direct sun penetratesthe space.

• Uplight on ceilings improves ware-house lighting. The uplight on white-painted ceilings serves several impor-tant functions. It makes the lumi-naires appear less glaring because itreduces the contrast between theluminaire and its background. It pro-vides soft, bounced light at the tasklevel, which helps wash out distract-ing shadows. It provides greater ver-tical illuminance on storage shelves.Finally, it provides a psychologicallift because the space appearsbrighter and more cheerful.

• Dock lights often create poor seeingconditions. Traditional dock lights do a poor job of lighting truck cavities because they use a narrow-beam PAR lamp to direct light deepinside the truck. Workers, forklifts,and materials cast very strong shad-ows that get in the way of the lightbeam, and the concentrated lightcauses uncomfortable seeing conditions for workers as they comeout of the truck. An improved docklight design would use a lower-brightness lamp and a larger reflectorsystem that provides more diffuselight into the truck.

DELTA MEMBERSBonneville Power Administration

Consolidated Edison Company of New York, Inc.New York State Energy Research and

Development AuthorityNortheast Utilities System

Rochester Gas and Electric CorporationLighting Research Center

DELTA STEERING COMMITTEERonald Appleton, Craig Ciranny,

Patricia Glasow, Roger Knott, Mitchell Kohn, Peter Morante, Frank Napoli,

Marsha Walton

“[In Shipping and Receiving,] the lightoverall is very good. The only problem islights on the dock doors.”

–Employee, Shipping and Receiving

Delta 6, Sony - Lighting Research Center

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