Machine Vision & Industrial Inspection AI worked example

Lighting Cost at 65% shifts using inspection lighting: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop shifts using inspection lighting to 65%, then walk the calculation through step by step. Estimate the annual operating cost of inspection lighting for a machine vision system, based on the number of lighting fixtures, annual cost per fixture, the proportion of shifts the lighting runs, and annual replacement costs.

The inputs for this scenario

  • Number of inspection lighting fixtures: 6 fixtures (held at the documented default)
  • Annual cost per fixture (power and maintenance): 85 $ / fixture / yr (held at the documented default)
  • Shifts using inspection lighting (% of total shifts): 65 % (the input this scenario stresses; the baseline uses 90)
  • Annual fixture replacement and spare parts cost: 320 $ / yr (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Variable lighting cost = fixtures x annual cost per fixture x utilization.
  • Total annual inspection lighting cost works out to 652 $ at these inputs, and this is the headline figure for the scenario.
  • Annual cost per inspection fixture works out to 109 $ / piece at these inputs.
  • Variable power and maintenance cost works out to 332 $ at these inputs.
  • Annual replacement and spare parts cost works out to 320 $ at these inputs.

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 16.37% below the baseline at 652 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to shifts using inspection lighting, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. 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: 652 $ (headline result)
  • Annual cost per inspection fixture: 109 $ / piece
  • Variable power and maintenance cost: 332 $
  • Annual replacement and spare parts cost: 320 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Lighting Cost calculator, set shifts using inspection lighting to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.