Lights Out Manufacturing With Hogge Precision As a result, a lights out setup might not be a worthwhile undertaking for small-scale production facilities. Developing a lights out production facility requires a significant financial investment and overcoming numerous operational hurdles to reach a point where everything functions optimally. Getting set up for lights out may require bringing in a systems integrator that can make sure all relevant systems communicate with each other. For example, connecting older machines to a new MES to run them in a lights out capacity may require overcoming a variety of glitches and obstacles. Lights out manufacturing requires a high degree of technical proficiency. The MES can also help to manage preventative maintenance schedules to proactively avoid issues. By employing an MES solution, staff gets notified about the need for maintenance should the equipment fall below its expected Overall Equipment Effectiveness (OEE). Since no workers are present during lights out manufacturing, there is no one around to address potential failures or malfunctions during off-hours. Incorporating an effective manufacturing execution system (MES) and robust connectivity hardware infrastructure will ensure visibility into real-time production data even when no one is present in the production facility. Operators must be able to access production equipment remotely from an internet-connected device. When they do, human intervention is needed. Even with the most advanced automated manufacturing technology, unforeseen issues can always arise. Fully autonomous manufacturing environments need to address these key issues in order to deliver accurate and reliable services. While lights out production comes with many significant benefits, there are also a number of challenges. Efficiency is also maximized in lights out manufacturing operations since fully automated machines can work without stopping.Īdditionally, the accuracy and precision of automated machine tools creates end products that are highly consistent, with little need for rework or secondary processing in many situations. Since the machines work continuously, a lights out facility’s manufacturing capacity increases greatly while total production costs diminish. There are many benefits to lights out production methods, with one of the most significant ones being cost reduction. The automated machinery handles the physical production aspect, while human workers plan production schedules, manage the facility, maintain equipment, and program the automated machine tools and other assets. To create a lights out operation, significant portions of the manufacturing process must be automated so extensively that the equipment continues production even after all workers have left the building and turned and turned off the lights-hence the name. Lights out manufacturing is a production method that requires minimal or no human interaction beyond initial programming and tooling setup. Lights-out factory help increase the overall efficiency and productivity of these assembly lines but even the most advanced lights-out factory will need people to load the programs, maintain the equipment, provide the raw materials, etc.Friday afternoon, everyone has gone home but our machines are still running. Īutomation helps reduce the monotony of manufacturing by taking over some of these tasks and freeing workers to shift their focus to other, more critical tasks. However common challenges can be seen in: it’s expensive high tech installation (with additional staff training also necessary) the set up is better suited for only simple tasks and slow emergency response. In theory, since robotic arms and assembly equipment don’t need ambient light to see as humans do, these manufacturing facilities could function in total darkness without any adverse effects on quality, efficiency, or productivity.īenefits of lights-out manufacturing can be seen in: fewer workplace accidents (with no humans to get hurt!), Less waste and better quality (through the automated production of the same quality and consistency), and advancing maintenance strategies (with necessary predictive and preventive maintenance schedules running). Events in EIT Manufacturing Central regionsĪlso known as dark manufacturing, it is a relatively new methodology using automation to operate a facility without human intervention.The Best Practice Classes on Innovation Policy for Authorities.LEADERS: Women Innovators in Manufacturing.Meet Konstantinos Georgoulias, Pillar Director.Education Transversal Initiatives (Cross-KIC).PanTrack – Sensors for shopfloor safety.CanvAAS – bridging a fragmented industry landscape. V-Machina: Virtual Reality bringing together people and machines!.
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