Bay Lighting
Dongwon Steel, Czech Republic
Information
- Application
- Bay Lighting
- Location
- Dongwon Steel (Moravskoslezský kraj, Czech Republic)
- Light Source
- SEGA Series
- Support
- GigaTera Technical Team
-
The Start of Quality Innovation, Changing the Light
GigaTera's Light Awakens the Productivity of Dongwon Steel
- This project is a premier smart factory lighting solution in which the existing, aging metal halide lighting at the Dongwon Steel Czech factory—a global automotive parts supplier for Hyundai, Kia, and Toyota—was completely replaced with GigaTera's state-of-the-art LED high-bay lights and intelligent wireless control system to solve chronic quality issues and to maximize productivity and energy efficiency.
The Dongwon Steel Czech factory, which supplies key components to world-class automotive companies, obtained a detailed analysis concluding that one of the core causes of its persistent quality defects was a dark working environment (average 240 lux) that fell far short of the industry standard (500 lux). This was a challenge that urgently needed to be addressed, as it hindered not only worker safety and productivity but also the quality competitiveness of its products.
To solve this fundamental problem, Dongwon Steel chose GigaTera as its optimal partner. Through on-site measurements and precision simulations, GigaTera provided a solution that replaced the existing 450W metal halide lights with 160W high-efficiency 'SEGA' LED high-bay lights on a 1-to-1 basis. In addition to this, it created an intelligent lighting environment that went beyond a simple lighting replacement by also installing the 'Gess™ AIR' wireless dimming control system, which optimizes brightness according to the work situation and maximizes energy savings.
After the lighting replacement, the factory's overall average illuminance was dramatically improved by more than double, to 597 lux, far exceeding the target of 500 lux. Through this, a base energy saving rate of 65% was achieved, and when utilizing the wireless dimming control system, an innovative energy saving effect of up to 85% was obtained.
The most important achievement was that the project realized its original goal of improving quality. The color temperature, which prioritized the visual comfort of the workers, and the much brighter illuminance directly contributed to increasing the work efficiency of the employees and lowering the product defect rate, revitalizing the entire factory.
- Impact and Value
-
• Laid the foundation for quality improvement with a more than 2-fold increase in average illuminance (240 lux → 597 lux)Download Case Study
• Achieved an innovative energy saving rate of up to 85%
• Established a smart factory environment with the 'Gess™ AIR' wireless control system
• Increased worker efficiency and maximized productivity
• Met the demanding quality standards of a global automotive parts supplier
