7
Production
“Design by ORION” lighting is manufactured almost exclusi-
vely in the ORION light factory in the Liesing district of Vienna,
combining Austrian craftsmanship with automated, customer-
focused series production. Every light goes through a number
of production stages, from design development to the raw ma-
terials processing through to the assembly of individual com-
ponents and final inspection.
Development & Design: Everything starts with a plan …
The story of each ORION-light begins long before production. It
starts with a blueprint of the construction – meticulously develo-
ped from the idea over the production concept to the final “De-
sign by ORION”. A sample item of each new light is made and cri-
tically studied. If it meets ORION’s demands, then it either turns
into a product series or is manufactured as resolution of a special
project.
Process Planning: … which turns into a check-list
A so-called itemized check-list is compiled for every light, con-
taining all its components. As soon as it is available for every
light model the actual manufacturing order can be processed. All
necessary materials order picked and the individual departments
supplied with them.
Basic Materials: A premium quality foundation
Most ORION lights have a base made of brass, an alloy of cop-
per and zinc. To maintain identical high quality standards over
the course of many years, we endeavor to obtain all brass from
the same producers. Currently these are mainly manufacturers
in Germany. Brass as basic material is superior to iron, as it is
stainless and thus of high durability. This quality comes at a price
– not only is brass more expensive, but also more demanding in
workmanship.
Workshop: Precision (every step of the way)
The raw materials for our lights first enter the workshop. Using
various processing methods, the individual components receive
their basic form: Blanking in the pressure press, disconnecting,
drilling, bending, soldering, milling and cutting threads. The work-
shop employees carefully control every piece before it moves on
to the surface finishing departments.
Grinding and cleaning shops: The first polish
On arrival, the components are first treated mechanically. Smal-
ler light components lose their rough edges in steel ball polishing
machines; large ones are manually ground piece by piece. In the
next step the parts are degreased and chemically cleaned to eli-
minate any residue before the premium ORION finishing.
Electroplating and paint shop: True colors
As soon as the components are clean, they “take a bath” in the
fully automated electroplating department – to receive the fine
gold- or chrome-shine the ORION lights are admired for. Surfaces
such as “Bronze” or “Patina” are hand-shaded afterwards to ob-
tain their characteristic micro-sectioning. Afterwards the compo-
nents receive their final finish in the paint shop, where all parts
are covered in a protective varnish which is then case-hardened
in ovens at app. 120° degrees Celsius. ORION uses an electro-sta-
tic paint procedure. Once more every component separately un-
dergoes yet another a strict quality control. Incidentally: Degre-
asing as well as electroplating create polluted industrial sewage.
For all procedures in the lighting factory to be as environmentally
friendly as possible, the ORION factory has its own purification
plant in which all sewage is treated before it re-enters the cycle
of use. Another ORION specialty. For us ORION quality means also
conserving the quality of our environment.
Assembly: Complex hand-craft
The individual components are assembled to completed lighting
fixtures in the assembly department respectively in homework.
We work with the “one on one” principle: All components of one
ORION light are assembled by one assembly worker: From linking
the crystal hangings over screwing together the basic frame to
arranging the final lighting composition. This helps avoid error
sources and lets us reach our superior quality level. The assembly
of crystal chandeliers for instance requires an incredible amount
of skilled handiwork.
Final Inspection& Packaging: Tested quality,
packaged for worldwide shipping
As soon as a light from the “Design by ORION”-series is finished,
it must undergo further testing: a visual test whether the light
has been assembled correctly and particularly whether the fi-
nishing is immaculate, an electric test checking the functioning
of the light. First series also go to the laboratory for certification.
If ORION lights have passed all tests, they are packaged, sent to
the distribution center and from there they go on the journey to
their final destination.
Quality meeting highest standards
