Manufacturers constantly look for ways to increase productivity, improve machine utilisation and produce more. Lights out manufacturing offers a practical way to achieve these goals.
Instead of stopping production when the working day ends, manufacturers can use robotics and automation to keep equipment running with minimal intervention. As a result, businesses can increase production capacity, improve consistency and make better use of their existing machinery.
This approach works particularly well in CNC machining. By combining CNC equipment with industrial robots, automated material handling and intelligent control systems, manufacturers can create highly efficient lights out machining cells.
However, successful automation requires more than simply placing a robot beside a CNC machine. Manufacturers need to consider the entire production process, from material presentation through to finished-part handling.
At Automated Solutions Australia (ASA), we help manufacturers integrate FANUC robotics into industrial automation systems. Therefore, we understand how robotic machine tending can help businesses move towards more efficient and flexible production.
What is Lights Out Manufacturing?
Lights out manufacturing describes a highly automated production environment where machines can continue operating with minimal human intervention.
The concept gets its name from the idea that a factory could keep producing even after employees leave for the day and the lights go out.
In practice, however, lights out manufacturing does not mean removing people from the manufacturing process altogether. Instead, automation takes responsibility for repetitive and predictable tasks while skilled employees manage programming, maintenance, quality and production optimisation.
For example, a robotic cell can:
- Load raw material into a CNC machine
- Remove completed components
- Transfer parts between processes
- Perform repetitive handling tasks
- Present components for inspection
- Sort finished parts
- Communicate with production equipment
- Continue production outside standard operating hours
Consequently, manufacturers can create a more productive environment without asking employees to perform the same repetitive task throughout an entire shift.
How Does Lights Out Machining Work?
A typical CNC machining process requires an operator to load a component, start or manage the machining cycle, remove the finished part and prepare the machine for the next component.
A robot can take over much of this process.
First, the robot picks up a raw component from a designated location. Next, it loads the component into the CNC machine. The CNC then performs the programmed machining operation.
Once machining finishes, the robot removes the completed component. It can then place the part into a finished-goods area or transfer it to another process.
The robot can then repeat the cycle.
As a result, manufacturers can automate the repetitive movement between the operator and the machine. Furthermore, the same robot may be able to service multiple machines, depending on the production requirements and cell layout.
CNC Lights Out Manufacturing
CNC lights out manufacturing provides manufacturers with an opportunity to increase the utilisation of valuable CNC equipment.
CNC machines represent a significant investment. Therefore, manufacturers naturally want to keep that equipment productive for as much of the available time as possible.
During a conventional production schedule, a CNC machine may remain idle overnight or between shifts. However, automation can help extend its operating hours.
For example, a robotic CNC cell can automatically:
- Retrieve raw material.
- Load the CNC machine.
- Start the machining cycle.
- Wait for the machining process to finish.
- Remove the completed component.
- Place the component in the correct location.
- Load the next component.
- Repeat the process.
This simple sequence can dramatically reduce the amount of manual machine tending required.
Moreover, manufacturers can combine robotic machine tending with other technologies to create a more advanced production system. Depending on the application, the cell could include automated inspection, part tracking, vision systems, tool monitoring and production data collection.
Therefore, CNC lights out manufacturing can become much more than automated loading and unloading. It can form part of a connected manufacturing strategy.
Why Use Robots for Lights Out Production?
Robots provide the repeatability and flexibility that many lights out applications require.
Unlike a manual operator, a robot can perform the same programmed movement repeatedly. It can also work alongside multiple pieces of equipment when the system design allows it.
For example, one industrial robot could potentially tend multiple CNC machines. The robot could move between machines, load components, unload completed parts and manage the production sequence.
As a result, manufacturers can potentially increase machine utilisation without assigning an operator to every individual machine.
Furthermore, robotics can help manufacturers manage repetitive tasks that can become physically demanding over long shifts.
Instead of spending hours loading and unloading machines, operators can focus on activities that require greater judgement and technical expertise.
These activities may include:
- Production planning
- Quality control
- Robot programming
- CNC programming
- Preventative maintenance
- Process optimisation
- Troubleshooting
- Tool management
Therefore, automation does not simply replace a manual task. Instead, it can change how manufacturers use their skilled workforce.
The Role of FANUC Robots in Lights Out Manufacturing
When manufacturers explore robotic lights out manufacturing, they need to consider reliability, reach, payload, cycle time and integration requirements.
FANUC robots offer a flexible platform for many industrial automation applications. At ASA, we integrate FANUC robotics into production systems designed around each customer’s specific requirements.
For CNC applications, a FANUC robot can handle repetitive machine tending while the CNC equipment performs the machining process.
However, the robot itself represents only one part of the solution.
A successful robotic cell must bring several technologies together.
These can include:
- FANUC industrial robots
- CNC machinery
- Robot controllers
- End-of-arm tooling
- Material storage
- Part presentation systems
- Safety equipment
- Machine interfaces
- Vision systems
- Inspection equipment
- Production monitoring
When these components work together, manufacturers can create a coordinated production cell rather than an isolated robotic application.
What are the Benefits of Lights out Production?
Manufacturers can achieve several benefits by introducing lights out production into suitable applications.
1. Increase Machine Utilisation
First, automation can help manufacturers keep machinery productive for longer.
Rather than stopping production at the end of a shift, a suitable automated cell can continue processing components with minimal intervention.
Therefore, businesses can potentially get more output from equipment they already own.
2. Extend Production Hours
Lights out automation can also extend production beyond standard operating hours.
For example, a manufacturer could run an automated cell overnight and have completed components ready for the next working shift.
As a result, the business can increase production capacity without necessarily extending employee working hours.
3. Reduce Repetitive Manual Handling
Machine tending involves repetitive movements. Operators may need to load and unload hundreds or even thousands of components over time.
A robot can perform these repetitive movements consistently.
Consequently, employees can spend less time on repetitive handling and more time on higher-value manufacturing activities.
4. Improve Production Consistency
Robots follow programmed movements with a high degree of repeatability.
Therefore, a well-designed robotic system can provide consistent handling throughout the production cycle.
This consistency can help manufacturers create a more predictable process, particularly when the system combines robotic handling with automated inspection and process monitoring.
5. Increase Production Capacity
Manufacturers often want to increase output without immediately investing in additional machinery.
In some applications, automation can provide another option.
By increasing the utilisation of existing CNC equipment, businesses may be able to produce more parts from their current production assets.
However, every application differs. Manufacturers should assess their production volumes, cycle times and equipment capabilities before deciding whether lights out automation makes commercial sense.
Is Lights Out Manufacturing Completely Unattended?
Not always.
This distinction matters because the term lights out manufacturing can create the impression that a factory can operate indefinitely without human involvement.
In reality, successful automated production still requires people.
Manufacturers need to maintain equipment, replenish materials, manage tooling, monitor production and respond to unexpected issues.
The goal is therefore not to eliminate human involvement. Instead, the goal is to minimise unnecessary manual intervention.
For example, an automated cell might run unattended for several hours. However, employees may still prepare material before production begins and inspect the system when they return.
Furthermore, manufacturers can design automation systems to detect certain faults and stop safely when necessary.
Therefore, effective lights out production relies on good automation design, not simply leaving a machine running overnight.
How to Build a Robotic Lights Out Manufacturing System
Creating a robotic lights out manufacturing cell requires careful planning.
First, an automation integrator needs to understand the existing manufacturing process.
Next, the team can identify where automation will deliver the greatest benefit.
From there, the system can be engineered around the production requirements.
Step 1: Assess the Process
Start by analysing the current process.
Look at cycle times, production volumes, operator movements, machine utilisation and material handling.
This assessment helps identify the tasks that offer the strongest opportunity for automation.
Step 2: Select the Robot
Next, select a robot based on the required reach, payload, speed and application.
The robot must also fit within the available production space.
Step 3: Design the Tooling
The robot needs the right end-of-arm tooling to handle the components safely and consistently.
Depending on the application, this could involve grippers designed specifically for the component geometry.
Step 4: Integrate the CNC Equipment
The robot and CNC machine must communicate effectively.
The automation system needs to understand when the machine is ready, when machining has finished and when the robot can safely enter and exit the machine.
Step 5: Design Material Handling
The robot also needs reliable access to raw material and completed components.
Therefore, the system needs an effective method for presenting components to the robot.
Step 6: Integrate Safety Systems
Safety remains fundamental.
The automation cell needs appropriate safeguarding, access control and safety functions based on the application and relevant requirements.
Step 7: Test and Optimise
Finally, the complete system needs testing.
The integrator can then optimise robot movements, cycle times and production sequences before the system enters full production.
As a result, the finished automation solution can provide a reliable foundation for longer and more efficient production runs.
Is Lights Out Manufacturing Right for Your Business?
If your business operates CNC machinery, produces repeatable components and wants to increase machine utilisation, lights out manufacturing could provide a valuable opportunity.
Move Towards Lights Out Manufacturing with ASA
Lights out manufacturing gives Australian manufacturers an opportunity to rethink how they use automation, robotics and CNC equipment.
Instead of allowing machines to sit idle between shifts, manufacturers can automate repetitive processes and keep production moving for longer.
Furthermore, CNC lights out manufacturing can help businesses improve machine utilisation while reducing repetitive manual machine tending.
However, successful lights out machining requires more than a robot. It requires the right combination of robotics, tooling, machine integration, safety systems and process design.
At Automated Solutions Australia, we specialise in integrating FANUC robots into industrial automation systems. Our team can help manufacturers assess opportunities for robotic machine tending and develop automation solutions around their production requirements.
Whether you are investigating lights out production, CNC automation or a complete robotic lights out manufacturing system, the right automation strategy can help you take the next step towards more productive manufacturing.
Ready to explore what lights out manufacturing could look like for your production line? Contact Automated Solutions Australia to discuss your application.
