8
final assembly
The assembly shop houses several sub-assembly
lines and the final assembly line. Sub-assembly lines
handle the assembly of doors, dashboard, locks etc.
On the assembly line, all components, parts and
sub-assemblies are fitted to the body, both inside
and outside. Two systems of assembly shops are in
use: a conveyor-based production process and a
platform-based production process. As well as the
assembly tasks, logistics and transport are the main
activities. Most assembly is performed manually.
Lighting recommendations
Illuminance Corridors: 200 lux
Normal assembly: 500 lux
Fine assembly:
750 – 1,500 lux
Uniformity Corridors:
E
min
/ E
ave
> 0.5
Line horizontal:
E
min
/ E
ave
> 0.8
Line vertical:
E
min
/ E
ave
> 0.4
Luminance Limited, no bare lamps visible
Color temperature Neutral
Color rendering R
a
≥ 80
Workers on assembly lines perform repetitive
work. High lighting levels and freedom from glare
are essential for optimizing productivity. For this
reason, asymmetrical luminaires suspended at a
height of 2.5 meters, in addition to a general
lighting installation, are required. If the car bodies
are moving on a conveyor line and workers are
moving during the task either along or inside the
car, continuous light lines are preferred over
intermittent lines.
Task lighting luminaires are mounted at rather
low heights to allow light to penetrate deeply
inside the car. Impact-resistant luminaires will
have a significantly longer lifetime than those of
a delicate construction. Open luminaires allow the
desired lighting effects to be created more easily.
For assembly work, the vertical illuminance is
often more important than the horizontal light
level. Attention should therefore be given to the
use of luminaires with wide-beam light distributions,
or with batwing light distributions. For each
specific location, an optimal lighting solution can
be created. However, plant engineering requires
universal solutions so that activities can be shifted
along the assembly line without costly adaptation
of the luminaire layout.
For moving-platform systems, the lighting
installation should either be part of the platform
system, or a high-level general lighting installation
should be used. If the platforms move during the
task, care must be given to avoid flicker from
non-continuous light lines.
Typical lighting installation
The most common combination is the use of
advanced asymmetrical (closed) luminaires with
task lighting optics, simple industrial aluminium
reflectors or white-painted reflectors for
general lighting.
AUTOMOTIVE INDUSTRY LIGHTING
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