What is Lights Out Manufacturing?

Lights out manufacturing has become a popular topic of discussion across many different industries.  

Advancements in AI, robotics, and other cutting-edge technologies have lowered the barrier of entry to fully automated systems for manufacturers, which is known as lights-out manufacturing. While designing a completely automated system is still out of reach for many businesses, there are benefits to embracing the tools and techniques of these systems even today. 

What is Lights Out Manufacturing? 

Simply put, lights-out manufacturing is an operation that relies entirely on automated machines without the need for human intervention.  

As the name suggests, an entirely automated system could run without any lights on. The robots and automated systems involved in each process function without the need for human supervision, intervention, or control.   

While there are currently only a handful of entirely lights-out manufacturing facilities, the trend toward automation is clear. As labor becomes a limiting factor in business growth and the cost of entry for automated systems and technology is reduced while the ROI grows, more companies see lights-out manufacturing as an appealing option. 

What Are the Benefits of Lights Out Manufacturing? 

Compared to traditional manufacturing processes, a lights-out system has many advantages. It reduces the need for human employees to perform monotonous work, frees up time to handle more delicate or complex duties, and automates dangerous tasks to help reduce workplace injuries.  

Here are a few additional benefits of working with a lights-out system: 

Increased Productivity 

Eliminate the need for regular downtime during human break periods. Automated systems can work overnight and never call in sick. One of the most exciting benefits of automated systems is increased productivity. If your productivity is held back by a lack of staff or by your inability to continue production outside of regular hours, lights-out systems can provide an immediate advantage in increased production time.

Increased Safety 

Production can involve dangerous activities even when a manufacturer is operating a safe facility that is up to all safety guidelines and regulations. Complex manufacturing processes often involve large moving parts, high temperatures, and fluctuating air conditions. Safety regulations and practices can keep your team safe, but they can only go so far, and human errors can happen even with the most stringent practices. Automated systems remove the human element from even the most dangerous processes, increasing overall safety.  

Reduced Costs 

Designing, constructing, and programming a lights-out system is expensive, but these facilities pay for themselves over time. The ROI for automation has increased as the costs of the equipment have gone down and manufacturers realized increased production uptime and higher throughput. The initial costs of an advanced automated system may be high, but it’s become a safe investment for many companies.  

How Can OTC Help You Achieve a Lights Out System? 

Designing a system that runs with only minimal human supervision isn’t easy.  

Thankfully, there are readily available resources to help you reach your goals. The experts at OTC understand what it takes to create fully automated facilities and can recommend the right equipment and practices for you. As an end-to-end manufacturing solution provider with expertise in automation, equipment, and more, they can deliver expertise, planning, design, and equipment. Here are just a few of OTC services that can help you create a lights-out manufacturing operation.

Equipment Recommendations from the Experts 

With an extensive catalog of automation equipment, OTC has all the latest parts needed for a lights-out system. More than just an equipment distributor, OTC also has expert teams that can walk you through lights-out designs.   

Engineers Who Can Design Your Lights Out Approach 

If you don’t have a full team of engineers working on the blueprints of your new facility, there’s no need to worry. OTC’s engineers have experience designing and executing automation plans and have experience providing input when needed with your project team. With specialists in various manufacturing practices, OTC can provide product support and engineering when needed.  

Access to Strategic Teams That Reduce Your Staffing Requirements 

After creating a lights-out facility, you will need additional support for maintenance and upkeep. This includes on-hand replacement parts and a preventative maintenance schedule. Thankfully, OTC can help reduce pressure on your staff with solution-focused services and on-call support. Services like DIRECTAIR® act as a managed compressed air solution, a utility you can rely on to keep your business running.  

Discover All the Ways OTC Can Help 

Whether you’re looking to design a new facility, renovate an old one, or just want to learn more about the state of automation technology, we want to help.  

Our expert teams are standing by to answer your most important questions, so contact us today.