Automation and robotics really don’t need lights on to do their work. They also don’t have to stop working at the end of an 8, 10, or 12-hour shift.
Humans can’t do that. What if a wall panel factory could turn out the lights and head home for the night? That would be a game-changer for production.
Lights-out manufacturing, also known as dark manufacturing, is a relatively new methodology that uses so much automation that a facility can operate without human intervention.
Lights-Out manufacturing had its start in about 2001. Even though it’s still in its infancy, it is maturing quickly with many manufacturing facilities installing automation and robotics in the most repetitive stages of production.
In Lights-Out manufacturing, human workers should only be needed on-site for emergencies or routine maintenance. Some manufacturing facilities are looking for Lights-Out operations during the third shift because human workers often struggle to adapt to these strange overnight hours.
Looking at the most repetitive stage in any building, the walls, floors, and trusses, it could make a lot of sense for panelized manufacturers to begin looking at building factories with Lights-Out as the blueprint of production.
From stocking the lumber to applying the sheetrock or exterior paneling to robotically built walls, floors, and trusses and then stacking them in the proper order of assembly at the job site may soon see some players in the market invest in a totally Lights-Out factory.
Even new modular home factories could have a section of their facility producing wall panels during a second shift getting walls built for the balance of the production line.
What are the benefits of lights-out manufacturing?
Fewer Workplace Accidents
It’s easier to keep workers safe and prevent injuries or accidents on the job if there isn’t anyone there to get hurt. Safety protocols are still essential for maintenance crews or human workers in the facility, but injuries are kept at a minimum for normal operations.
Less Waste and Better Quality
One of the most significant benefits of automated manufacturing is that, unless something goes very wrong with the equipment, it will be able to create the same quality and consistency every time. That means better overall products shipped to the consumers and fewer recalls or discarded production runs, which creates less general waste.
Cons of Lights-Out Manufacturing
Expensive High-Tech Installation
Getting the automated systems necessary for a lights-out factory isn’t easy or cheap. The technology is relatively new, so cutting costs by opting for used equipment isn’t always an option. These systems need to work together seamlessly, with little to no human intervention. The initial installation can be expensive and additional training is necessary to ensure everyone on staff knows how to set up, work with, and maintain the automated systems.
Better for Simple Manufacturing Tasks
Lights-out manufacturing setups are better for simple and easily repeatable tasks. Complex manufacturing tasks or plans are more difficult to program into an automated system. The more steps something takes to assemble, the more chances there are for errors to occur. It’s not impossible to set up a lights-out factory for complex manufacturing tasks, but the technology is better suited to simple tasks.
Slow Emergency Response
If something goes wrong or catches fire in a traditional factory, there are team members around to respond instantly. Things can get messy quickly if something goes wrong in a lights-out factory.
Humans are problem solvers and creative spirits and will continue to innovate and change the manufacturing industry for the better. Lights-Out manufacturing is just one step in the right direction. These innovators are building an automated future that will continue to shape the manufacturing industry and economy for decades.
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Gary Fleisher is the Editor in Chief of Modular Home Source and Offsite Builder. Email at [email protected]
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