Published: May 22, 2025  Updated: May 16, 2025

Exploring Lights Out Manufacturing and Dark Factories

Do you know the future of manufacturing and other industries? It might include something known as "lights out" manufacturing, or "dark factories." In this article, we'll explore this type of operation and discuss the following:

• What Is Lights Out Manufacturing?
• Advantages and Disadvantages of Lights Out Companies.
• Industry Examples Of Lights Out Manufacturing.
• Maintenance's Role In A Lights Out Environment.
• How a CMMS Supports a Lights Out Company.

What is lights out manufacturing?

What if you could run a business 24/7? Production never stops—material in, processed, final product out, hour after hour. You'd need a lot of manpower, right? Or, you'd rely on automation, robotics, artificial intelligence, and minimal human supervision.

In essence, the factory can function with the lights turned off, hence the name. This concept has existed for many years, and certain companies and industrial sectors have experimented with this or gone this route. No humans, only machines.

Sound a little like science fiction? Perhaps. But read on for current companies following this.

Advantages and Disadvantages of Lights Out Companies

Why would any company decide to turn out the lights, so to speak? Here we have several benefits.

• Production and efficiency. Put this at the top of the list. Robots can work tirelessly without breaks, reducing production time and increasing output. Furthermore, by automating many tasks, manufacturers can reduce labor costs and overhead expenses.
• Quality products. With automation, you have fewer chances of human error.
• Versatility. Since you don't have humans, lights out facilities can operate in environments unsuitable for humans. Examples include operations with hazardous materials or extreme temperatures.

While the potential benefits are substantial, implementing lights out manufacturing comes with some obstacles.

• Initial investment. You probably will incur extra expenses for automation, robotics, and advanced technology.
• Planning. Before initializing the changeover, you should plan for as many contingencies as possible. These include maintenance activities, security, and employee transition, training, or redeployment.
• Security. The company's reliance on digital systems makes it an attractive target for cyberattacks. Any disruption to these systems can halt production and cause substantial financial losses.
• Product complexity. Lights out manufacturing excels at high-volume, standardized production, but it may struggle with products requiring frequent adjustments or customization.
• Backup system. According to an article from Machine Design, you'll need to incorporate backup energy systems in case you experience a power outage.
• Impact on Supply Chain. According to the same article, you should discuss with your vendors, delivery companies, warehouses, and the like how they will cope with the increased production.
• Type of Automation. An article from MIT Management suggests companies look for "robot designs that are more accessible and adaptable." You don't want a complexity that inhibits alterations, adjustments, or modifications without extensive downtime.

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Industry Examples Of Lights Out Manufacturing

Lights out manufacturing has found its niche in industries with high production volumes and relatively simple products. Where should you look for this type of operation? The automotive, electronics, and semiconductor sectors started blazing the trail. For example, many automotive plants have automated assembly lines capable of producing thousands of cars daily with minimal human involvement.

In the electronics industry, companies like Foxconn have implemented lights out manufacturing for producing smartphones and other consumer electronics.

Other industries looking at lights out include fish processing as discussed at the National Library of Medicine.

One particular company, photography giant, Canon, looks to gradually adopt more automation.

Maintenance's Role In A Lights Out Environment

With more automation and more robotics, you must consider the maintenance aspect. Ensuring the uninterrupted operation of a lights-out factory hinges on proactive strategies. These include predictive maintenance, enabled by IoT sensors and data analytics. These systems can monitor equipment health in real-time, predicting failures before they occur and allowing for scheduled maintenance.

Also, you can't forget preventive maintenance. Regular inspections and calibrations of robotic systems and automated machinery. Remote monitoring and diagnostics to identify and address issues promptly.

Additionally, you should still employ a skilled maintenance team on standby, even if the factory operates lights out. Unexpected breakdowns always lurk around the corner.

Also, keep in mind spare parts management is another critical aspect. Even this, though, can operate through automation.

Discover how streamlined maintenance processes can elevate production. Learn more.

How a CMMS Supports a Lights Out Company

Lights-out manufacturing, characterized by heavily automated processes and minimal human intervention, presents unique challenges and opportunities for maintenance practices. A Computerized Maintenance Management System (CMMS) plays a crucial role in ensuring the smooth and efficient operation of such facilities.

Here are several key functions of a CMMS in a lights-out manufacturing setting:

• Predictive Maintenance: Don't underestimate the importance of predictive maintenance, enabled by IoT sensors and data analytics. A CMMS can integrate with these systems to collect and analyze real-time data on equipment health. This allows for the prediction of potential failures before they occur. By identifying patterns and anomalies, the CMMS can trigger maintenance work orders, schedule interventions, and minimize downtime. This proactive approach is essential in a lights-out environment where there are minimal human resources to detect problems.
• Preventive Maintenance: You can't forget about the need for preventive maintenance, and a CMMS is the foundation of any preventive maintenance program. It helps in scheduling regular inspections, calibrations, and servicing of robotic systems and automated machinery. The CMMS can track maintenance schedules, generate work orders automatically, and ensure that all necessary maintenance tasks are completed on time. This systematic approach reduces the risk of unexpected breakdowns and extends the lifespan of the equipment.
• Remote Monitoring and Diagnostics: A CMMS can facilitate remote monitoring and diagnostics, which are critical in a lights-out setting. The system can provide a centralized platform for maintenance teams to monitor equipment status, performance metrics, and potential issues from a remote location. When a problem is detected, the CMMS can alert the appropriate personnel and provide diagnostic information to help them understand the issue and plan a response.
• Spare Parts Management: Sometimes, even spare parts management can be automated. A CMMS can play a vital role in this by tracking inventory levels, managing procurement, and automating reordering processes. It can also help optimize spare parts inventory by identifying critical spares, minimizing stockouts, and reducing carrying costs. This ensures that the necessary parts are available when needed, minimizing downtime in the automated factory.
• Centralized Data and Reporting: A CMMS serves as a central repository for all maintenance-related data, including equipment information, maintenance history, work orders, and performance metrics. This data can be used to generate reports, analyze trends, and identify areas for improvement. In a lights-out environment, this data-driven approach is essential for optimizing maintenance strategies, improving efficiency, and reducing costs.
• Integration with Other Systems: To maximize its effectiveness in a lights-out setting, a CMMS should be integrated with other systems, such as Enterprise Resource Planning, Manufacturing Execution Systems (MES) and Supervisory Control and Data Acquisition (SCADA) systems. This integration enables seamless data flow, improves coordination between different departments, and provides a holistic view of the manufacturing process.

What's the Future of Lights Out Industries?

What is lights out manufacturing, and should humans worry? Currently, a handful of companies have greatly minimized or eliminated a human production force. Technology continues to advance. Companies look to cut costs and remain productive.

Artificial intelligence has grown so much in only a short time. Where will it grow tomorrow? Already, we have AI involved in writing, video production, and imagery. What's next? Overseeing manufacturing?

Robotics and automation have also grown. Many industries use them, especially automakers and electronics. As technology continues to advance, we can expect to see more and more factories adopting a lights-out model.

However, the human element will likely remain essential. While robots can handle repetitive tasks, they can't replace human ingenuity, problem-solving, and adaptability. Maybe mankind should look to a balanced approach, combining the strengths of humans and machines.

Ultimately, lights-out manufacturing represents a step towards the factory of the future, where you have increased production, conserved resources, and enhanced quality and delivery speed of products.

For more discussion about this topic, read a discussion from the University of Cincinnati.

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