Quality products “Made in Germany”
Unlike many other companies, we have gone the furthest in incorporating the individual production steps in our production process. JB-Lighting is the only manufacturer in Germany that independently develops intelligent moving lights with LED technology for professional use – on approx. 2,500 m2 of production space – and manufacturers everything in-house except for a few components. We don’t just do the final assembly on site, but all the related steps in manufacturing – from development and design, to prototyping, mechanical series production, and further processing of electronic parts.
No compromises in quality, performance or efficiency
All steps in work and production are always completed with a quality and function check of the manufactured parts, so that any potential defects are virtually excluded in the preliminary stages.
Due to the continuous upgrading and flexible construction of our entire production facility, we are not only able to manufacture in a very demand-oriented way, but also react to trends in the lighting industry with flexibility at any time, act independently of suppliers to the greatest extent possible and promote our developments.
With JB-Lighting, “Made in Germany” is guaranteed
Because we best meet our quality standards with our own well-trained staff, we decided to carry out as many production steps in-house as possible. While the final assembly and a limited manufacturing facility had already been incorporated from the beginning, other departments were established and expanded over the course of the last 20 years.
This means we’re in a position to effectively meet our standards and your requirements regarding design, excellent technology, functionality, processing, performance and service life.
Short paths and decision-making processes throughout the entire production operation
We are therefore able to determine the most effective paths to production for a spotlight in advance. For this reason, we can offer our products in a price segment that is not a matter of course for German brand-name products.
This has allowed us to develop a solid and satisfied customer base whose feedback is vital for further developing our products.
Consistent Light and Color Quality
In industrial production of LED modules, color variations may occur due to tolerances in light color. Consistent color binning ensures quality and guarantees that JB luminaires emit a uniform light color with no visible differences.
Although the LED modules delivered to us have already been measured by the manufacturer, we scan them again, sort them by their bin category, and store them accordingly. CMY color wheels are also subjected to in-house binning using a transmission spectrometer and sorted according to various classes (bins).
In the following, there is an overview of our departments and the respective production steps. Comprehensive quality and function tests are carried out at the end of each manufacturing process.
DEVELOPMENT
Work steps from the initial ideas to the prototype
- Project studies, market and requirements analysis
- Development and design of mechanics, electronics and unit design by experienced engineers and technicians with the aid of modern CAD software/hardware
- 3D simulation and calculation (CFD program)
- Development/programming of unit software
- Extensive tests in our in-house testing lab up to series production and CE certification
- In-house prototype construction
MECHANICAL PRODUCTION
Work steps in the turning shop
- Programming/equipping of metalworking machinery
- Production of rotary parts made of plastic, steel, aluminium, brass
- Manufacture of gears for series production
Work steps in sheet metal shaping
- Stamping and straightening of sheet metal parts
- Pressing in insertion tools such as nuts, bolts, sockets, etc.
- Edging and embossing
- Vibratory finishing
- Regrinding of punching tools
PCB ASSEMBLY
- SMD assembly
- vapor-phase soldering
- Assembly of displays
- Import of software
Quality control
- Each board undergoes a visual inspection and a final function check on the test board
CABLE ASSEMBLY
- Assembly of different cables
- Stripping and crimping of different connectors
- Configuration of complete wire harnesses for final assembly
- Tinning quality control
- Testing the manufactured crimp and plug connection
MANUFACTURE OF GOBOS AND COLOUR PANELS
- Gobo manufacturing for series production
- Lasering of dichroitically coated colour discs
- Laser marking of sheet metal parts
Quality control
- Visual inspection
- Inspection and categorization of CMY color wheels for color deviations and nuances (binning)
FINAL ASSEMBLY
- Commissioning of all necessary parts for assembly
- Manual assembly of lights by riveting, screwing, gluing, and soldering
- Packaging in cases or cartons
Quality control
- Multi-hour functional test of each completed unit
- Colour balance according to reference product
- Measurement of the insulation resistance
- Measurement of the earth resistance
WAREHOUSE
- Storage of in-house production and purchased parts
- Picking parts for production orders in final assembly
- Incoming inspection/LED binning: Scanning and labeling of delivered LED modules according to light color/color value
- Plotting various films
- Picking and packing goods for shipping
