Preventing Energy Loss in the Lighting System

In the production line, approximately 50 lighting fixtures rated at 250 W each were controlled independently of machine operating conditions. As a result, lights could remain on when the production li...

24 September 2026

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KAIZEN A3 REPORT

Mini Kaizen - Quick Improvement

Team:

BEFORE

State before kaizen

Approximately 50 lighting fixtures rated at 250 W each were installed along the production line.
Lighting was controlled independently of machine operating conditions.
Lights could remain on when the production line was not operating.
Areas that did not require lighting could also remain illuminated.
This resulted in unnecessary energy consumption.
The lighting system was not linked to actual production conditions.

A production line with multiple lighting fixtures operating independently of machine status. Lights remain on even when machines are not operating, creating unnecessary energy consumption.
Main message:
Lighting was controlled independently of production conditions.

Caption: A production line with multiple lighting fixtures operating independently of machine status. Lights remain on even when machines are not operating, creating unnecessary energy consumption. Main message: Lighting was controlled independently of production conditions.

AFTER

State after kaizen

The lighting control system was redesigned according to production conditions.
Each machine's operating signal was connected to the lighting system.
Additional fixtures were installed at the beginning and end of the line.
These fixtures provide lighting when the entire line is switched off.
Lighting now operates according to actual need.
Approximately 217 kWh/year of energy savings were achieved.
Reported unit saving: approximately 62 TL/fixture/year.

The production line after the lighting control improvement. Machine operating signals are connected to the lighting system, allowing lights to operate according to production conditions. Additional fixtures at the beginning and end of the line provide sufficient illumination when the full line is switched off.
Main message:
Light where needed, when needed.

Caption: The production line after the lighting control improvement. Machine operating signals are connected to the lighting system, allowing lights to operate according to production conditions. Additional fixtures at the beginning and end of the line provide sufficient illumination when the full line is switched off. Main message: Light where needed, when needed.

Problem Statement / Theme

In the production line, approximately 50 lighting fixtures rated at 250 W each were controlled independently of machine operating conditions. As a result, lights could remain on when the production line was not operating, including during periods when lighting was not required.

The lighting control system was redesigned according to the operating condition of the production line.

Each machine's operating signal was connected to the lighting control system. Additional lighting fixtures were also installed at the beginning and end of the line to provide sufficient illumination when the entire line was switched off.

With this arrangement, lighting is activated when it is needed and automatically controlled according to production conditions.

Result: Approximately 217 kWh/year of energy savings were achieved.

Lean principle:
The best energy-saving opportunity is often not using less energy, but preventing energy from being used when it is not needed.

Preventing Energy Loss in the Lighting System

KAIZEN A3 REPORT

BEFORE

AFTER

Problem Statement / Theme

Team Formation

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