The Client
Lightolier/CFI, a member of the Genlyte Thomas Group LLC family of companies, is a leading manufacturer of lighting fixtures and controls for commercial, industrial and residential markets.

The Challenge
When Lightolier’s equipment began to age, they knew it was time for an upgrade. Christian Rheault, Manufacturing Manager, relied on Lightolier’s long-standing relationship with Gema USA to build a new system that was right for their operation.

The Solution
Lightolier upgraded to a complete OptiSystem from Gema USA. The upgrade also included an 8,000 cfm Vortech™ powder booth and an AutoTracker™ Programmable Logic Control (PLC) that was integrated with their computer network.

The Savings
Lightolier has been able to increase both line speed and product density, easily meeting their expanded production requirements. Due to better transfer efficiency, they also achieved powder savings of 28%. They expected a return on their investment in eighteen months, but achieved it in less than 6!

“Prior to our upgrade to the OptiSystem™ we were producing 2,500 parts per day running ten shifts per week. Now we can produce 4,300 parts per day with only eight shifts — and we’re still improving!”
— Christian Rheault, Lightolier/CFI

Please note: The above Case Study has been prepared by Gema USA, a supplier of Modean Industries, and is being reproduced with Gema USA’s permission. Hani Azzam of Modean Industries supervised the design and engineering of several of the original Gema systems in the United States.