LIGHTS OUT FACTORIES

PRESENTED BY:

PANKAJ SHARMA 121755

BATCH: E2 SEMESTER: 6

LIGHTS OUT MANUFACTURING METHODOLOGY

Lights out or lights-out manufacturing is a manufacturing methodology (or philosophy), rather than a specific process.

Factories that run lights out are fully automated and require no human presence on-site. Thus, these factories can be run with the lights off.

Many factories are capable of lights-out production, but very few run exclusively lights-out. Typically, workers are necessary to set up tombstones holding parts to be manufactured, and to remove the completed parts.

As the technology necessary for lights-out production becomes increasingly available, many factories are beginning to utilize lights-out production between shifts (or as a separate shift) to meet increasing demand or to save money.

A BRIEF HISTORY

The term lights-out in reference to manufacturing has been around since the early eighties, often associated with the late Roger Smith, CEO of General Motors, who envisioned a fully-automated car manufacturing process which would make the company as efficient as its Japanese rivals. Unfortunately, the associated machinery didn't turn out to be up to the job, even with the lights on, and the term slipped into obscurity for many years until improved technology made lights-out manufacturing a realistic and attractive option.

The term itself is based of course on the idea that having no humans present in a place of work means 'the lights can be turned off'. In practice it's not only the lights, but the heating, air-conditioning, kettles, microwaves and other things humans might need too, making substantial savings on running costs.

Dating back to the 1950s, an earlier term for a similar concept is automatic factory, which describes a factory where raw materials enter and finished products leave with little or no human intervention.

HUMANS AND ROBOTS This methodology is not completely human-free. Lights out manufacturing is not as simple as setting up a job and letting it run. It requires careful planning, experienced workers, programming, maintenance, and upkeep. This generation of robotics works with people, rather than replacing them, giving companies the opportunity to optimize the way their team works on a daily basis. Manufacturing has transformed from dirty and labor intensive, to a high-tech workplace. Automation is at the core of this shift, pushing companies with tech power to dominate the marketplace.

UNDERSTANDING LIGHTS OUT vs AUTOMATION

The term "lights-out" has two essential uses in

manufacturing. One is factory automation that is designed

to use robots in place of human labor for high-volume,

repetitive production of a single part or assembly. This is

often used in the automotive industry, either to produce

component parts or, more commonly, to build portions of a

vehicle on an assembly line.

ADVANTAGES OF LIGHTS OUT

There are several advantages of lights out manufacturing that benefit the day-to-day operations as well as impact the long-term success of manufactures.

Added productivity Minimal impact on labor costs Reduces the labor required to keep equipment operating Allows companies to focus on hiring highly skilled workers & utilized their technical skills and knowledge Energy Efficiency- Ability to turn off electricity, while lowering heating & cooling temperatures during the overnight hours Increased operating efficiency & competitive edge

EXAMPLES 1. PHILIPS

Philips uses automation from Adept technologies to make its electric razors.

2. FANUC

FANUC has been a market leader in automation and builds industrial robots along with other automation machinery. And apparently these robots are build by other robots (automation) eliminating the need of human interference

3.MIDWEST ENGINEERING SYSTEMS

Midwest Engineering System’s has helped companies in the food and beverage industries design and build palletizing and deplletizing systems that run on a lights out mentality. In the palletizing example, a forklift automatically loads the system with individual cases and robots pick the cases, put them into place, and stacks them onto pallets. These pallets are then stacked one on top of another in a dedicated area. These systems are left alone over periods of time without human supervision.

SHEDDING LIGHT ON THE FUTURE

Not all automation projects can be run entirely lights out; more complex jobs will require assistance. But, it enables less people to be involved. One person can supervise many machines that run automatically rather than one operator per machine. With this information, robotic-based automation still has huge potential for manufactures of all sizes.

For the optimal lights-out plan, design, equipment, installation, training, and service for your operation, contact Midwest Engineering Systems. As an experienced integrator, we provide process engineering, programming, reporting, tooling, and so much more.

Innovative automation systems will be the future of manufacturing growth.