Overall concept for where I work is that I
track every lamp costing us between about $73.00 and $2.4K per lamp in
stock. That’s a good thing but with over 16,000 lamps tracked (most in their demise but still on the computer
tracking), I have a good data
base for studying lamp failure tendancies, lot number problems, brand problems and other stuff. Also, I can even tell should a
fixture serial number be removed, what serial number that
fixture is by way of the lamp in it. This beyond being able with some experience being able to save money on re-testing at times twice or a third time once rejected as being dim or off in
color temperature, if it still looks good to me, trying it in another
fixture and much of the time it works out just fine with a different
ballast. This beyond say about a 1%
return of lamps for reimbursement rate. Lamp is listed for X amount of lamp hours, if not operator error and if you can document the history of the lamp and confirm the lamp being dim, failing before 2/3's of its expected lamp life, that’s a lamp that goes back to who sold it to you. A few months later after traveling to Europe for inspection, and if you have a valid claim on it you either get a replacement lamp or a refund on it. That’s
SOP for expensive or any lamps as long as you can
track them properly. Know of some companies sister to us that have a bucket of good lamps and a bucket of dim lamps that depending on what
profile the show is they are prepping them for they choose the lamps for. Ain’t how we work and in doing lamp
tracking we get back given around 2,500 moving light lamps bought per year, around 300 to 600 lamps worth of refund per year by way of
tracking each lamp as an individual lamp.
Takes a very good organization of course and I constantly curse or yell at the free lance and or others of staff that don’t when changing lamps just accurately fill out like five lines of text on each replacement lamp box because in a realistic sense - for each moving light lamp without it’s pedigree, that’s one day rate of an employee less. Those wishing there were more help to prep a show or out on a show to me I simply note how much we waste a year in lamps in comparison to that extra body’s salary per year.
Just five, now six lines of text to fill out on each box. Each box when recieving it gets inspected for quality and it’s serial number gets noted on the outside of the box before the lamp sticker gets placed on the box. Each new lamp is than logged into the computer with the date of arrival, who it was bought from and what
purchase order it was bought under. A sticker or three is than placed on the box. First sticker - them Osram stickers if Osram that come with the lamps - something like “Caution Shark XS inside”. Any sticker that says caution is good for me in hopefully helping prevent the broken on install lamps percentage. And if just left in the box, tech people are like kids, we would start seeing the sickers everywhere - a note the Osram rep. in me complaining about the stickers seemed to take some “I Know” humor about. Second sticker is one I have fought Osram and Philips about, one I pay to have made for me. It’s the lamp wattage. Last week I had our first 1.2Kw
Mac 2K lamp installed into a
Mac 2K XB
fixture. This as opposed to about a year or two ago the constant install of
Mac 700 lamps installed into
Mac 2K fixtures. Simple 1"x3" stickers placed on each box given all boxes are the same and the actual lamp description is in small print helps tremendously to prevent the wrong lamp from being money down the drain after it fails at about 400 hours when in the wrong
fixture. This or marking the boxes with high lighter colors or sharpee wattage of lamp type stuff helps prevent people from pulling the wrong lamp. Same issue with 1.2Kw verses 2Kw FastFit lamps, really difficult given the same boxes to prevent.
Third sticker is the world for me in
tracking lamps. Just five lines of text to fill out, yet beyond Ronald McDonald having changed the lamp at times as if a joke, amazing how few people in seeing five blanks to fill out either attempt to fill out any, or just leave out a few blanks, even one. Ok, if the lamps’ in the box - assuming they have any lamp in the box or just one in the box, also problems at times, I can get the serial number off that lamp as needed so that’s the least important blank to fill in. Lamp installed into the
fixture is already marked on the box so what lamp is removed from the
fixture which is now in the box is a little less important for someone to put on the box. But on the other
hand, if someone is changing say one lamp and I’m typing into the computer say sixty lamps per day, there is a big difference in needing to look at the small print for those with one instead of one with sixty say to look at.
Still that’s the least important
line to fill out and one that don’t anger me because it won’t
effect warranty on the lamp. I can fill that one in as needed.
Other lines are date - date of lamp change, just sent an Email out to someone who put as date 12/23. Hmm, it’s 12/18 and I have been sitting on these lamps for a few weeks now. Do you not even know if it’s two days before Christmas? Still I was by him at least filling in that, assume he meant 11/23 as opposed to others that don’t and I now have no idea of when not just the lamp was removed, but when the new lamp was installed. Simple as a date - busy, can you fill such a
line in later perhaps??? Same with who changed the lamp. If a problem, it’s good to be able to contact them. Took a few years but even MR.
IATSE #2 finally started filling out his lamp sheet, name of person that changed the lamp is still prefered but what ever the case, it’s a blank to fill out, what’s difficult about that? Get boxes back with “bad” written across this form. Gee, that’s helpful.
Next
line after name is reason for replacement. “I said so...” yea, that’s helpful. Two “dim’s” or a dim and a brown equal a lamp sent back after being tried twice for a full refund on the lamp if under 2/3's its expected lamp life - within reason and not if for other reasons. I average about 100% refunds these days but have a few thousand lamps under the belt inspected for submitting such lamps. Still a lamp confirmed to be bad not in just one
fixture but two and it’s probably bad. Ronald McDonald saying he says so’ means we start over on the lamp at best if not
throw out any chance in being honest with a valid lamp history of why it was rejected and throwing the money down the hole because someone was being funny at the expense of a day rate of someone’s salary per day.
Every lamp for me means one person’s day rate in pay and I inspect them with that in mind.
So, dim, brown, yellow,
etc. help in describing why the lamp on seeing it in use was replaced is helpful. Otherwise at times when first the fixtures are opened up for cleaning before bench focused in fixtures one to another, such weather conditions about what the
globe looks like is acceptable if later in the lamp life. “Snowball” is common even if just cloudy, frosty and snowstorm for what the
globe looks like. Leave the weather forcast to me but often those saying such stuff for reason for rejection are fine in saying so based on the concept that such stuff on the
globe will prevent light from getting out or graphically light from getting out as a small pinpoint source of light. Reason for replacement in those instances is valid - looked at the lamp and it’s looking like it won’t be around long in other words. Another valid for me “reason for replacement” reason is “Hours.” Got a few tours that have been out for over a year now and might be out for a few more years without
return. They are doing good in replacing 750 hour rated lamps at around 800 to 1200 hours by way of the realistic extent the lamps will life and group replacement of all of them. By that time, the lamps are trash, and on long tours lamps often do last long beyond their expected lamp life when left alone or with a long tour or install persay one don’t realize the
drop in output as much overall with lamp life.
So reason for replacement for me is a good thing of note in sending the lamps back if under 2/3 lamp life, and otherwise what’s noted about the lamp. Beyond that next is details often very important.
Frequently fixtures show up to rehearsal and never get to the shop. I don’t get the ability often for a new
fixture as I like to for the initial lamps install into the computer that lamp’s serial number with seller of the lamp, date of delivery,
fixture serial number for us as with manufacturer bar code, and
purchase order. Often it’s “unknown install” and a lot of ??? for other stuff. Them lamps unless I do a lot of computer work have no chance of warranty replacement. So, another
line on the sticker on each replacement lamp is
fixture serial number. Not the manufacturer serial number/bar code, our serial number that’s a little less extreme in numbers. If I get the lamp/
fixture list for new fixtures before the show leaves I can if barcode number figure out a
fixture number otherwise, but if not filled in or better yet if someone says say A2 for what
fixture number that was on the
plot... that’s useless to me and often a reason I cannot
send back a lamp.
Granted people are at times hanging 40' up in the air up side down in changing lamps - no doubt always doing so, or the people changing the lamps those supervising them are either intimidated into not asking too many questions of or too lazy as the case of our shop manager it would seem amongst the worst in filling out the lamp data... what ever the case, if I have info on a past lamp install in the computer, often within a few minutes I can figure out what
fixture it is in. Otherwise as with above, it’s either a “lost” lamp no longer valid
return or something with link to up to three past lamps not valid but at least I can fill in the black hole for some day as to what
fixture they were assigned to. Shouldn’t be that difficult but often it is.
Than the most important question - lamp hours. You know, some older fixtures don’t
track lamp hours and that’s fair enough, but if you as a “professional” are doing your job, you are resetting the lamp hours on the
fixture anyway so there is no reason why one would not at very least be able to fill this blank in. Heck, for some xenon lamps to get a warranty claim on them I also need strikes and if not burst modes on them, for a
HMI lamp, it is still just lamp hours I need. What’s so difficult about filling this most crucial of all blanks? Often the most not filled in blank but often also even if not for
return the most telling about the
fixture. Going
thru a lot of lamps? Could it be a lot number or perhaps the
fixture? How to
track if not for lamp hours and a
fixture history?
Sure, I can estimate the amount of hours a lamp has been in use but it’s not valid for
return. Above all else lamp hours as tracked by the
fixture and you get anyway in doing your job by way of resetting the lamp counter you have anyway. Yet frequently the only thing left off the tag to fill in meaning a lamp that cannot be returned.
Added to this recently another just blank to “X” off for six things now to fill out. “Lamp
Socket Changed?” Wouldn’t believe the amount of lamps I get back with failures due to bad
fixture lamp sockets, and in seeing them but being back logged I don’t have a chance to ask if they also changed the lamp
socket. Some crew chiefs in me sending e-mails after the second or third bad lamp due to a bad
socket in a
fixture asking about the
fixture automatically tell me if
socket changed, others it does take a total melt down of the
socket before they change the
socket - this in wasting a few hundred dollars worth of lamps before they note the condition of the
socket.
My job to inspect lamps for cause of failure, one would think that of those changing the lamps also in doing their job, but not the case in the field it would seem in often once a bad
fixture socket it often not changed until about the second or third lamp past when it’s bad. With the new
line to fill out, hopefully at last as with “lamp counter reset” the person changing the lamp and filling out the sticker (one with our company name and phone number on it also, plus “
return all bad lamps”) will if for a moment pay attention to the lamp
socket that’s 1/5 the price of a lamp.
Anyway, a simple tag to fill out on each replacement lamp box. Simple enough to fill out or within reason fill out as best possible within limited amounts of not being able to fully. Constant battle for me and the largest thing that stands between a bad lamp in the trash and one that can get returned for credit. Just a few lines of text that lets me fill out that lamps’ history on the computer.
For those lamps without serial numbers, between graphite pencil and engraving tool, every lamp that goes out my door has a unique serial number or I don’t by that brand of lamp. Saving money at times aint’ worth the effort at others in attempting to
track them.