AutoParts Mexico S.A. manufactures precision automotive components in their 3,200 sqm facility in Monterrey. The existing T5 fluorescent lighting provided inadequate illumination for quality inspection, leading to a 2.1% defect rate and frequent worker complaints about eye strain.
Challenge
- Inconsistent light levels (150-400 lux) across production lines
- 2.1% defect rate partly attributed to poor lighting during QC inspection
- Annual lighting cost: $42,000 with frequent tube replacements
- Pressure from automotive OEM clients to meet sustainability standards
Solution
Installed 80 units of 200W LED high bay with CRI>90 in inspection areas and standard CRI>80 in general production. Integrated motion sensors in storage zones and daylight harvesting near skylights.
Results
- Uniform 500 lux across all production areas (3x improvement)
- Defect rate reduced from 2.1% to 0.8% within 6 months
- Annual energy cost reduced to $24,000 — saving $18,000/year
- Carbon footprint reduced by 45% (12.6 tonnes CO₂/year)
- Full ISO 14001 compliance documentation provided