What is Lights Out Manufacturing? The Future of Automated Production

Manufacturers are dealing with worker shortages and higher costs. Consequently, more are starting to use lights-out manufacturing. This means running factories with little or no human help to save money and work more efficiently.

A Gartner study says that by 2025, 60% of manufacturers will have more than two fully lights-out processes. These will be in at least one of their factories.¹

This article explores lights-out manufacturing, its benefits, real-world examples, and the challenges companies face in adopting this approach.

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What is Lights-Out Manufacturing?

Lights-out manufacturing is a fully automated production process that requires little to no human presence on-site. In these facilities, machines, robots, and software systems work independently, even without the lighting, heating, or cooling typically required for human workers. These facilities are often called dark factories. That’s where the term "lights-out" comes in.

The concept hinges on advanced automation technologies like robotics, artificial intelligence, machine vision, and digital twin systems. These tools enable continuous, 24/7 operation, reducing downtime and maximizing efficiency.

Role of Robotics and Automation in Lights-Out Manufacturing

Lights-out manufacturing is an ecosystem of robotics, automation, and AI-driven systems that work in harmony. This is to eliminate the need for constant human oversight.

Industrial robots handle repetitive, high-precision tasks such as welding, assembly, packaging, and inspection.

Advanced automation also extends to logistics and internal movement. Automated guided vehicles (AGVs) and robotic arms move materials between workstations. Sensors and machine vision systems perform real-time quality control. In some setups, machine learning algorithms
monitor performance and adjust workflows on the fly.

The integration of cloud-based platforms and smart controls also powers lights-out digital manufacturing. This enables remote monitoring, predictive maintenance, and seamless coordination between systems.

One standout example is advanced lights-out robotic cell manufacturing, where compact, fully enclosed robotic cells perform complex operations autonomously.²

Benefits of Lights-Out Manufacturing

Lights-out manufacturing offers a wide range of benefits, including:

Cost Savings and Increased Efficiency

One of the most significant benefits of lights-out manufacturing is reduced operational costs. With minimal human involvement, companies save on labor expenses and energy consumption. There is no need to light or climate-control unoccupied spaces, and errors caused by fatigue or inconsistency.

24/7 Production with Minimal Human Intervention

Another advantage of lights-out automated manufacturing is continuous operation. Robots don’t need breaks; systems can keep running overnight, on weekends, and during holidays without interruption.

What Are the Disadvantages of a Fully Automated Factory?

While lights-out manufacturing offers numerous advantages, it's essential to consider the potential challenges and drawbacks associated with fully automated factories:

High Initial Investment Costs

Light-out manufacturing requires a substantial upfront investment. This is because of advanced robotics, automation technologies, and digital infrastructure. The cost of acquiring and integrating these systems can be significant.

Technical Issues and Maintenance Requirements

While efficient, automated systems are not immune to technical glitches. A malfunction in a fully automated environment can halt production. This can lead to downtime and potential revenue loss.

Limited Flexibility and Adaptability

Lights-out manufacturing systems are typically designed for specific tasks. They may not be flexible enough to adapt quickly to changes in product design or customization requests.

What Companies Use Lights-Out Manufacturing?

Several industry leaders have adopted lights-out manufacturing. This is to boost productivity, reduce costs, and maintain precision in high-volume operations.

Fanuc (Japan)

One of the most well-known pioneers of lights-out automated manufacturing, Fanuc operates a factory that runs 24/7 without human workers. It runs for up to 30 days. The facility produces CNC machines and robotics, i.e., robots used to build robots.³

Haas Automation (USA)

Haas, a machine tool manufacturer, incorporates lights-out manufacturing into its operations to run unattended shifts. Its facilities rely on CNC automation, and robotic cells to keep production operating overnight with minimal supervision.⁴

Siemens

Siemens Lights Out manufacturing initiatives are well documented. The company integrates digital twin technology, AI-driven process optimization, and robotic systems to achieve high levels of automation in electronics and energy component manufacturing.³

Philips (Netherlands)

Philips operates a highly automated dark factory for electric razors in the Netherlands. The facility runs with minimal human input. It uses robotic arms and smart monitoring systems to maintain high output and quality control standards.⁵

How Much Does it Cost to Implement Lights-Out Manufacturing?

The cost of implementing lights-out manufacturing varies widely depending on the scale, industry, and level of automation required. But it’s safe to say that the initial investment can be substantial, with expenses including:

• Robotic systems and machinery
• Sensors, PLCs (programmable logic controllers), and IoT infrastructure
• Custom software and system integration
• Facility upgrades or retrofitting for automation compatibility
• Employee training and cybersecurity measures

For example, a small to mid-sized manufacturer might set up one advanced lights-out robotic cell. The cost can range from $250,000 to $750,000. The price depends on how complex the system is. This can be a big investment for many companies.⁶

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Sources:
Lights-Out Production Will Be a Reality by 2025
https://standardbots.com/blog/robotic-work-cells
Full Automation: The Path to Lights-Out Production | Machine Design
Haas Robot & Cobot packages
Automation, robotics, and the factory of the future | McKinsey
Robotic Welding Cell Cost in 2025 | CLOOS NA
All sources checked June 2025