Let There Be Light

Re-View recently had a "Green" experience that could help many companies of all types.



We were founded 18 years ago on the basic principle of resisting the status quo, and are constantly searching for ways to advance our organization. Our plant manager had been reading several studies about how proper lighting can improve the quality of work and increase productivity. Given this information, he commissioned a study on how to effectively improve the lighting in our window plant. He was motivated to use efficient changes in lighting to improve the throughput in the plant. He was also convinced that increases in lighting in certain areas would reduce defects and rework.



What our plant manager didn't realize was how changes in light fixture and bulb technology could dramatically impact the electrical consumption of our plant. We brought in a lighting consultant who evaluated the current fixtures and the illumination throughout the facility. Our management then established target foot-candle ratings for the different areas of the plant, increasing the levels in areas where precision work was performed.



Like many production facilities constructed in the late 1960's, our plant has a combination of sodium vapor high bays and T12 fluorescent drop lights used to illuminate working areas. The lighting consultant quickly identified how we could achieve a three-year payback by replacing our existing system with six-lamp T5 fixtures. The team took a CAD drawing of our plant layout and established a lighting plan that would achieve 30 foot-candles in general areas and 50+ fc in areas where product detail is critical.



We recently tested the installation and discovered that in the assembly and fabrication areas of the plant where we used to have 15-20 fc, we now average 58-60 fc, and all shadows are eliminated. The aisles had 7 fc before the change and now are averaging 30 fc. Our plant employees are now asking for sunglasses and sunscreen.



The team at Re-View is always looking for ways to improve product quality and to reduce costs. We have invested in automated CNC fabrication equipment, computer-controlled saws, computerized glazing, and automated finishing systems. We came across many reports documenting improvements in productivity that were directly associated with changes in lighting. Since our windows are furniture-level quality, we were confident that advances in lighting would enable our craftsmen to perform better work. We also read reports about official improvements in employee satisfaction and safety due to upgrades in lighting. More information on the benefits of lighting can be found on this link: http://www.lightcorp.com/PDFs/industrial/learn/ImpactProductivity_DD1A8.pdf




What our team didn't realize was how advancements in lighting fixtures could also significantly reduce our electricity costs. We are going to recognize a payback on the investment in fixtures and the labor to install within the first three years. That is an amazing return especially since we aren't including the other effects of productivity and quality improvements that will certainly be achieved. Our results profoundly prove that Green building practices really do pay.

The Panes of Putty

A customer of mine commented the other day that putty glazing windows is a lost art and I would have to agree with him. As is the case with any art form, there are many hidden challenges in the proper usage of glazing compounds. I am going to address the problems to avoid when finishing glazing putty.

Glazing putty is a mix of boiled linseed oil, calcite lime, inorganic fillers and other common elements. The most popular brand is DAP 33, but there are other manufacturers such as Sarco that produce the similar material. It takes a great deal of practice and patience to become proficient at forming the putty in a straight line and tooling crisp corners. You can find several articles and YouTube videos that might help in accelerating your learning curve. A link to the DAP product data might also be helpful: http://www.dap.com/docs/tech/00010401.pdf

Most people have no concept of how long it takes for glazing compound to cure. Inexperienced users are astounded to discover that it can take up to three weeks to cure depending upon temperature, humidity, and thickness of the application. We have been able to reduce the curing time by introducing heat and fans in a specially designed curing oven. The biggest mistake we have seen in the use of putty is when it is finished prior to proper curing. When this occurs, the paint finish will lose its adhesion and display bubbles, cracks, and wrinkles. It is essential to wait until the glazing has skinned over and attained a firm set prior to applying any finish.

Another problem can occur if the wrong combination of finishes is applied to the glazing compound. Many people want to avoid the priming stage of finishing, which can be catastrophic. A good oil-based primer should be used prior to applying two coats of latex finish paint. Since the putty is linseed oil based and since the compound is flexible and continues to move as it fully cures, the superior adhesion qualities of an oil-based primer is essential. Failure to properly prime the putty can cause your finishes to delaminate.

One should also be careful in using certain finishes over glazing compounds. This especially occurs when putty is used to glaze steel windows. Most finishes designed for metals are not designed with the same elasticity and flexibility of traditional latex-based paints commonly used in wood finishes. The manufacturers of fluoropolymer paints and other steel finishes state that their finishes are not flexible enough to be applied over glazing putty. This type of finish is considered a rigid system and it will crack and eventually delaminate with any movement or thermal expansion or contraction of the glazing material.