GM’s Lordstown assembly and stamping complex, home of the North American-market Chevrolet Cruze compact sedan, has converted to LED lighting with a built-in and fully-integrated wireless control system. The conversion, which represents GM’s largest in North America, was conducted with the goal of replacing the existing 40-foot high bay lighting system in the stamping plant with one that provides the same amount of brightness and illumination yet costs less money, consumes less energy, and requires less maintenance.
The plant ended up achieving all three of its goals, including:
- Expected cost savings of $800,000 from replacing 1,328 (1,000 watt) and 283 (400 watt) existing fixtures with 1,246 LED solid-state lighting fixtures ranging from 90 to 360 watts.
- Expected energy consumption reduction of 84 percent, with a CO2 reduction of about 8,500 metric tons.
The new lights are expected to operate maintenance-free for more than 150,000 hours, and are equipped with a fully-integrated and built-in wireless control system, which allows operators to schedule lights in certain parts of the plant at certain intensities to follow production schedules, while dimming fixtures during breaks and between shifts. The plant removed fluorescent night lights and used selected high bay fixtures during non-production hours.
“We saw this project as a great opportunity not only to enhance lighting in our facility and realize significant annual energy and maintenance savings, but also to do our part to reduce our carbon footprint as a company and help General Motors continue to be a leader in innovative, green technology solutions,” said Lordstown Complex manufacturing engineering director Steve Rhoades.
“With 6 million square feet of buildings and lighting, there is a tremendous opportunity to become the benchmark in green energy solutions, as well as save a lot of money,” Rhoades said.