Machine Vision & Industrial Inspection AI worked example

Lighting Cost at 99% shifts using inspection lighting: a worked example

What does the result look like when shifts using inspection lighting reaches 99%? The full calculation is worked below with real intermediate numbers. Use it when budgeting annual operating costs for a machine vision inspection line and you need to include lighting power, maintenance, and replacement costs in the total cost of ownership.

The inputs for this scenario

  • Number of inspection lighting fixtures: 6 fixtures (unchanged)
  • Annual cost per fixture (power and maintenance): 85 $ / fixture / yr (unchanged)
  • Shifts using inspection lighting (% of total shifts): 99 % (raised for this scenario; the documented default is 90)
  • Annual fixture replacement and spare parts cost: 320 $ / yr (unchanged)

Working through the calculation

  • Applying the documented formula (Variable lighting cost = fixtures x annual cost per fixture x utilization) to the inputs above produces each figure below.
  • At this operating point the engine returns 825 $ for total annual inspection lighting cost, the number this scenario is built around.
  • At this operating point the engine returns 137 $ / piece for annual cost per inspection fixture.
  • At this operating point the engine returns 505 $ for variable power and maintenance cost.
  • At this operating point the engine returns 320 $ for annual replacement and spare parts cost.

How this compares with the baseline

  • Against the tool's baseline example, where shifts using inspection lighting sits at 90% and the headline result is 779 $, this scenario comes in 5.89% above the baseline at 825 $.
  • A figure at this level is achievable when shifts using inspection lighting is genuinely sustained, not just peaked for a shift. It treats running cost as a flat annual figure scaled by shift utilization, so it won't capture power tariff changes, peak-demand charges, or fixtures that fail faster under heavy duty.

Results at a glance

  • Total annual inspection lighting cost: 825 $ (headline result)
  • Annual cost per inspection fixture: 137 $ / piece
  • Variable power and maintenance cost: 505 $
  • Annual replacement and spare parts cost: 320 $

Run it with your numbers

  • Every input above is editable in the live Lighting Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.