2. LIGHTS OUT MANUFACTURING METHODOLOGY
Lights out or lights-out manufacturing is a
manufacturing methodology (or philosophy), rather
than a specific process.
Factories that run lights out are fully automated and
require no human presence on-site. Thus, these
factories can be run with the lights off.
Many factories are capable of lights-out production,
but very few run exclusively lights-out. Typically,
workers are necessary to set up tombstones holding
parts to be manufactured, and to remove the
completed parts.
As the technology necessary for lights-out
production becomes increasingly available, many
factories are beginning to utilize lights-out
production between shifts (or as a separate shift) to
meet increasing demand or to save money.
3. A BRIEF HISTORY
The term lights-out in reference to manufacturing
has been around since the early eighties, often
associated with the late Roger Smith, CEO of
General Motors, who envisioned a fully-
automated car manufacturing process which
would make the company as efficient as its
Japanese rivals. Unfortunately, the associated
machinery didn't turn out to be up to the job,
even with the lights on, and the term slipped into
obscurity for many years until improved
technology made lights-out manufacturing a
realistic and attractive option.
4. The term itself is based of course on the idea that having no
humans present in a place of work means 'the lights can be turned
off'. In practice it's not only the lights, but the heating, air-
conditioning, kettles, microwaves and other things humans might
need too, making substantial savings on running costs.
Dating back to the 1950s, an earlier term for a similar concept is
automatic factory, which describes a factory where raw materials
enter and finished products leave with little or no human
intervention.
5. HUMANS AND ROBOTS
This methodology is not completely human-
free. Lights out manufacturing is not as
simple as setting up a job and letting it run.
It requires careful planning, experienced
workers, programming, maintenance, and
upkeep. This generation of robotics works
with people, rather than replacing them,
giving companies the opportunity to
optimize the way their team works on a
daily basis. Manufacturing has transformed
from dirty and labor intensive, to a high-
tech workplace. Automation is at the core of
this shift, pushing companies with tech
power to dominate the marketplace.
6. UNDERSTANDING LIGHTS OUT vs AUTOMATION
The term "lights-out" has two essential uses in
manufacturing. One is factory automation that is designed
to use robots in place of human labor for high-volume,
repetitive production of a single part or assembly. This is
often used in the automotive industry, either to produce
component parts or, more commonly, to build portions of a
vehicle on an assembly line.
7. ADVANTAGES OF LIGHTS OUT
There are several advantages of lights out manufacturing that benefit the day-to-day
operations as well as impact the long-term success of manufactures.
Added productivity
Minimal impact on labor costs
Reduces the labor required to keep equipment operating
Allows companies to focus on hiring highly skilled workers & utilized their technical skills and
knowledge
Energy Efficiency- Ability to turn off electricity, while lowering heating & cooling
temperatures during the overnight hours
Increased operating efficiency & competitive edge
8. EXAMPLES
1. PHILIPS
Philips uses automation from Adept technologies to make its electric razors.
2. FANUC
FANUC has been a market leader in automation and builds industrial robots along with other automation
machinery. And apparently these robots are build by other robots (automation) eliminating the need of
human interference
9. 3.MIDWEST ENGINEERING SYSTEMS
Midwest Engineering System’s has
helped companies in the food and
beverage industries design and build
palletizing and deplletizing systems that
run on a lights out mentality. In the
palletizing example, a forklift
automatically loads the system with
individual cases and robots pick the cases,
put them into place, and stacks them
onto pallets. These pallets are then
stacked one on top of another in a
dedicated area. These systems are left
alone over periods of time without
human supervision.
10. SHEDDING LIGHT ON THE FUTURE
Not all automation projects can be run entirely lights out; more complex jobs will require
assistance. But, it enables less people to be involved. One person can supervise many machines
that run automatically rather than one operator per machine. With this information, robotic-
based automation still has huge potential for manufactures of all sizes.
For the optimal lights-out plan, design, equipment, installation, training, and service for your
operation, contact Midwest Engineering Systems. As an experienced integrator, we provide
process engineering, programming, reporting, tooling, and so much more.
Innovative automation systems will be the future of manufacturing growth.
