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Imagine CNC machines continuing to make parts after everyone has gone home for the night. That's the basic idea behind lights-out manufacturing.
Lights-out manufacturing uses automation to keep production running with little or no direct human involvement. Machines can continue working overnight, on weekends, and during other times when the shop is not fully staffed.
For customers, the important part isn't whether the lights are actually off. It's what this technology can provide: more production capacity, consistent quality, reliable delivery, and competitive pricing.
At Adept Manufacturing & Gauging, we use lights-out CNC machining to produce hundreds of thousands of precision parts each year.
Lights-out manufacturing is a production process that uses automated equipment to run without an operator standing at the machine.
In CNC machining, a lights-out system can perform many steps automatically. Depending on the job and equipment, these may include loading material, machining parts, removing finished parts, monitoring tools, and checking the production process.
Several technologies make lights-out manufacturing possible:
These systems allow a properly set up CNC machine to continue making parts even when employees are not physically in the building.
A traditional CNC machine may stop when an operator's shift ends. A lights-out machine can keep working. Running machines overnight and during unattended hours gives a manufacturer more productive machine time without adding another full shift.
For customers, that extra capacity can help shorten lead times and keep larger production orders on schedule. Learn more about our CNC machining capabilities.
Once a CNC process is proven and stable, automation can repeat that process again and again. This repeatability is especially valuable for production jobs that require thousands—or hundreds of thousands—of the same precision part.
A controlled process helps reduce variation and keeps parts consistent from one production run to the next. See how Adept approaches precision CNC machining.
Skilled CNC machinists are essential, but they don't need to stand in front of a machine for every minute of a long production run. Lights-out manufacturing allows skilled employees to focus on programming, setup, inspection, process improvement, and other work that requires their expertise.
Meanwhile, automated machines can continue producing parts. Using both people and automation efficiently can help control production costs and support competitive pricing.
More available machining hours give a shop more flexibility when scheduling production. A machine that can run overnight has more time available to complete an order than one limited to staffed shifts.
Automation doesn't eliminate the need for skilled machinists. Lights-out production depends on them. Experienced people develop the process, program and set up equipment, select tooling, verify quality, solve problems, and make sure the job is ready for unattended production.
Automated CNC equipment, tooling, monitoring systems, and related technology require a significant investment. Adept has already made that investment so customers can benefit from lights-out production without buying the equipment themselves.
A lights-out job must be thoroughly planned and tested before it can run unattended. Tooling, material, programming, part handling, and the machining process all need to be reliable.
Lights-out machining works especially well for repeat production jobs with stable processes. Highly customized parts, frequent design changes, or very small production runs may require more hands-on attention. We evaluate each project individually instead of trying to automate every job.
Adept currently operates three machines with lights-out capabilities. These machines produce hundreds of thousands of identical parts each year.
Our machinists set up and prove the process before unattended production begins. Once the job is running, remote monitoring helps us keep track of machine operation even when no one is in the shop.
Artificial intelligence and data analysis are becoming more important in automated manufacturing. Modern systems can collect information about machine performance, tooling, cycle times, and other parts of the manufacturing process. That information can help manufacturers identify problems and improve production.
Predictive maintenance is one example. Machine data can provide early warning signs of a potential equipment problem. Addressing the issue before a breakdown can reduce unexpected downtime.
See more about automation and other CNC technology trends.
Lights-out manufacturing will continue to grow as CNC machines, robotics, sensors, and monitoring systems become more advanced. But that doesn't mean factories will operate without people.
For precision CNC machining, the most effective approach is often a combination of skilled people and automation. People develop the process, solve problems, verify quality, and make critical decisions. Automation allows a proven process to continue producing parts for more hours each day.
If you need a repeat order of precision CNC-machined parts, lights-out manufacturing may help reduce cost, increase capacity, and improve delivery.
Have a repeat production job that may benefit from lights-out machining?
Send us your print and quantities. We'll review your project and determine the best way to manufacture it.