Ford Motor Company Dearborn, Michigan
ChallengeFor all automakers, attention to detail is critical. For Ford Motor Company, efficient operations and a safe and comfortable work environment are necessary to ensure those details do not get overlooked. In 2015, outdated HID and fluorescent lighting at Ford facilities in three different states were consuming too much energy, performing poorly, and requiring too much expensive maintenance. Worst of all, the legacy light fixtures were creating workplace challenges for Ford team members. The automaker needed to decrease energy consumption and increase task light levels at facilities it owned and operated in Kansas City, Kentucky, and at its Rouge facility in Dearborn, Michigan. To complete this ambitious lighting retrofit project, Ford knew it needed to partner with a lighting contractor with experience on projects at this scale. To get this logistically-challenging job done, Ford turned to FSG.
SolutionFSG brought Ford a custom solution designed to capitalize on the latest in energy-saving LED technology while maintaining and utilizing the existing electrical infrastructure at each facility. Working side by side with Ford management, FSG executed a multi-phase lighting retrofit program to meet Ford’s needs while ensuring minimal interference to normal plant operations. For this project, FSG was required to work around employee shifts to limit downtime at each plant. Additionally, FSG strictly maintained confidentiality requirements relating to Ford's manufacturing processes throughout the project.
ResultAt all three Ford facility locations, the lighting retrofit was executed smoothly and quickly with almost no impact on productivity for Ford. In all, 10,272 fixtures were replaced resulting in an annual 13,469,574 kilowatt reduction.
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