California Manufacturing Plant RetrofitAn auto parts manufacturing facility in California found itself struggling with an aging lighting network that drained maintenance budgets and failed to deliver the illumination needed for precision quality control. Flickering fixtures and uneven coverage jeopardized inspection accuracy, prompting leadership to search for a retrofit that balanced efficiency, reliability, and compliance with stringent production standards.ChallengeEscalating maintenance hours and spare-part costs were eroding margins, while inadequate light levels risked quality escapes on the assembly line. The plant needed a modern system that could stabilize illumination, reduce unplanned downtime, and stay aligned with lean manufacturing targets.SolutionEngineers executed a comprehensive retrofit using NGT-HB-150W LED high bay fixtures paired with NGT-FL-200W flood lights. The dual-layer design concentrated high-output light over work cells while reinforcing peripheral zones, creating an even visual field for inspections. Integrated control logic synchronized light levels with production schedules, limiting output during idle shifts and maximizing efficiency during critical QA windows.Results
Energy Savings – 65%: Cutting the connected load delivered immediate utility relief and lowered the facility’s carbon footprint.
Annual Savings – $45,000: Reduced energy consumption plus fewer emergency service calls turned lighting into a predictable cost center.
Utility Rebate – $28,000: Incentives from the local utility accelerated project payback and funded additional process improvements.
Payback Period – 1.8 years: Rapid return validated the business case and freed capital for further automation initiatives.
Why It MattersBy replacing legacy fixtures with targeted LED high bay and flood lighting, the plant now enjoys consistent lux levels across machining, assembly, and inspection areas. The upgrade supports tighter quality control, lowers maintenance exposure, and demonstrates how lighting retrofits can unlock both operational resilience and sustainability gains in manufacturing environments.
