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    Lights-out Manufacturing (Part 2)

    May 22, 2020 1:45:08 PM / by PlantStar Team


    lights-out manufacturing

    Welcome to part 2 of our lights-out manufacturing series. In (Part 1) we briefly discussed what lights-out manufacturing meant and then introduced you to the key benefits of such an approach. Those key benefits being reduced costs and increased plant efficiency. Today we want to look a bit deeper into the nuances of lights-out manufacturing and look more closely at some specific benefits that ultimately result in the over-arching cost saving and its improved efficiency goals. In case you missed our last blog entry, you can find it here (Part 1, Lights-out manufacturing). Now without further ado, let’s get into it!

    Lights-out manufacturing is an approach to manufacturing where a production facility is fully automated and the need for human intervention is all but eliminated. The actual term “lights-out” comes from the idea that in a fully automated facility, there is no longer a needlights-out3 for frivolous amenities such as lighting, as robot unions have yet to be invented and for now they are perfectly content with working long hours in the dark. At first glance, this seems like a dream come true for manufacturers, but in practice, as many early adopters have found, the challenges can be too much and oftentimes outweigh the benefits. We will take a closer look at some of these challenges in part 3 but for now, we want to explore the positive aspects of the illusive world of lights-out manufacturing.

    In a lights-out production facility, robots and computers run the show. There is little to no need for low-skilled labor and as a result, many of the costs and challenges that go along with one are gone. Having the ability to turn off the lights while production activities continue, is only the tip of the iceberg when it comes to the ultimate driving force behind the goal of a fully lights out facility. Below you will find our list of some of the additional benefits associated with a fully automated manufacturing operation.

    1. Decreased labor expenses. While it goes without saying that having fewer workers results in lower wage expenses, but it also means lower costs in terms of employee training, time off, and providing employee benefits and workplace amenities.
    2. Greater production consistency. Machine workers are more consistent in their production than human workers, simple as that. This in turn reduces the need for quality control, further expanding on the benefit.
    3. Energy efficiency. With robots in charge of production, factories are able to cut back on air conditioning, lighting and ventilation expenses. While small in itself, expenses like keeping a soda machine in the break room or a radio on in the sitting room can add up over time.
    4. Increased capacity. With lights-out production, manufacturers can get more done with less. Machines are able to continue production throughout the night and space previously allocated for human workers such as break areas and restrooms can now be utilized for more productive uses.
    5. Faster adjustments to changes in customer requirements. While many machines are one-trick-ponies, some can be programmed for a variety of uses. Should a new customer order come in that requires a completely different means of production, these machines are able to quickly pivot their operation as opposed to having to bring on a new human worker with an entirely different skill-set.

    This list is by no means exhaustive, but it does give you a pretty good idea as to the allure of having a fully automated, lights-out production facility. Be sure to subscribe to our blog so that you can be notified when we release our next blog post and we explore some of the challenges associated with lights-out production. In the meantime, if you're curious about some of the ways PlantStar can help you get a leg up on your competition and experience the benefits of lights-out manufacturing, click the button below and allow us to be your guide through this exciting digital revolution.


    Additional resources:

    5 Benefits of a Manufacturing Execution System (MES)


    Topics: Industry 4.0, lights-out manufacturing