This is the sixth of seven articles in our Automation and Robotics series. The others include What Is Industrial Automation Technology?, Robotic End Effector Guide, History of Robotics: Robotic Generations, Coding, and More, Autonomous Mobile Robots, Programming Robots, and Commercial Off-the-Shelf Software for Robots. An automated factory – sometimes referred to as a lights-out factory or dark factory – operates with minimal human intervention, often running continuously with machines, robots, and software handling most of the production processes. This type of computer-integrated manufacturing enables extended machining hours, consistent product quality, and reduced labor costs. While the concept of a fully unattended factory captures the imagination, most manufacturers realistically pursue lights-out processes within specific production cells rather than entire plants. In this article, we’ll explore the technologies and strategies behind lights-out manufacturing, including the types of machinery that can be automated, the differences between vertical and horizontal machining centers, tool management requirements, the ongoing role of human operators, the advantages and obstacles of fully automated production, the integration of AI, and the planning and software tools necessary to set up a modern automated factory. What Is Lights-Out Manufacturing? Advantages and Obstacles of Lights-Out Manufacturing What’s Required for a More Automated Factory Types of Machinery Suited for Computer-Integrated Manufacturing Tool Management in Automated Factories Human Roles in Automated Factories Software and Planning for Automated Factories AI in Automated Factories Examples of Full Lights-Out Factories The Future of Dark Factories Should Your Company Invest in Lights-Out Manufacturing?What Is Lights-Out Manufacturing? Lights-out manufacturing (or computer-integrated manufacturing) refers to production operations that can run with minimal or no continuous human intervention, often operating in environments where lights are unnecessary – hence the term. A lights-out factory, or dark factory, uses robotics, CNC machines, conveyors, and automated handling systems to perform tasks that would traditionally require human operators. In these environments, machines can continue production around the clock, even during nights, weekends, or holidays, with supervision performed remotely or on a scheduled basis. While the ultimate goal of lights-out manufacturing is a fully automated factory, most manufacturers today focus on partial automation, creating lights-out cells or dark manufacturing cells within larger facilities. These cells handle high-volume, repeatable processes – like machining, assembly, or inspection – without constant human oversight. At its core, lights-out manufacturing relies on careful planning, robust equipment, and monitoring systems that allow machines to detect errors, replace tools, and ensure quality. The process enables human roles to shift from performing repetitive tasks to designing, programming, and overseeing production systems. Advantages and Limits of Lights-Out Manufacturing Lights-out manufacturing comes with many advantages, such as increased throughput, reduced labor costs, and improved product consistency; however it also involves a high upfront investment, complex process planning, and the need for skilled personnel. Automated Factory Advantages When it comes to lights-out manufacturing advantages, automated factories can operate overnight or on weekends without human supervision, extending machining hours and maximizing throughput (PR Newswire). Fewer operators are needed, allowing labor to focus on higher-value tasks such as programming, quality assurance, and process optimization, while also reducing overall labor costs. Automation minimizes human error, producing more consistent and uniform products. Advanced scheduling boosts energy efficiency, enabling dark factories to reduce or even eliminate lighting and HVAC systems. Automation also improves workplace safety by reducing operator exposure to hazardous environments. Overall, the combination of lower costs and higher quality can help companies compete more effectively on a global scale. Lights-Out Manufacturing Limits Despite these benefits, fully automating a plant also comes with challenges (Pasha). Designing a lights-out manufacturing operation is complex and resource intensive. It requires meticulous upfront planning for process development and validation, including the setup and management of probing routines, robots and grippers, remote monitoring systems, and machine and tool maintenance. The high upfront investment, combined with the need for skilled personnel who understand robotics, programming, and process management, makes these operations most effective for high-volume, low-variation production (Lux Research). Even with all these systems in place, unattended factories carry the risk of downtime and costly failures if issues are not caught quickly. What’s Required for a More Automated Factory For manufacturers aiming to implement lights-out or highly automated production, several elements are critical for success; these include the right machinery, robust tool management, skilled personnel, and planning and software systems that can coordinate complex processes. Equipment must be capable of operating reliably with minimal human intervention, while tool and process monitoring ensure quality and prevent downtime. Skilled operators, engineers, and managers remain essential for programming machines, maintaining systems, optimizing workflows, and responding to exceptions. Software – ranging from manufacturing execution systems (MES) and enterprise resource planning (ERP) platforms to simulation tools and AI-driven analytics – helps orchestrate the machinery, manage schedules, track inventory, and detect potential issues before they disrupt production. Together, these components form the foundation for efficient, scalable, and resilient automated operations. Below, we explore each of these elements in more detail, including the types of machinery suited for lights-out manufacturing, tool management strategies, human roles, and the software and planning tools that make fully automated production possible. Types of Machinery Suited for Computer-Integrated Manufacturing Machining centers, laser cutters, and injection molding machines can be fully automated, but most manufacturers start with lights-out or dark manufacturing cells – dedicated zones containing multiple machines and integrated robotic material handling – before attempting full-factory automation. These cells focus on high-volume, repeatable tasks, allowing companies to optimize processes, test automation strategies, and limit risk. Over time, multiple cells can be connected or expanded, forming fully autonomous production zones capable of continuous operation with minimal human oversight. While CNC machining centers are the most commonly cited example of lights-out manufacturing, a growing range of machinery can now be fully automated: Horizontal machining centers (HMCs): Well-suited for automated production with high throughput and robot-friendly layouts. Vertical machining centers (VMCs): Can be automated with additional systems like robots, conveyors, and pallet staging. Injection molding machines: Ideal for lights-out factories because of highly repeatable cycles and consistent output, often used in medical, automotive, and electronics production. Press brakes and laser cutters: Can be integrated with robotic material handling systems for dark factory operations. Grinding and polishing cells: Robotic arms and conveyors manage repetitive finishing tasks, reducing human labor and increasing precision. Additive manufacturing systems: Automation of powder handling, post-processing, and quality inspection allows continuous production with minimal intervention. Assembly cells: Robots can assemble, test, and package products without human oversight, forming modular lights-out manufacturing cells. Automated storage and retrieval systems: Deliver raw materials and collect finished goods, supporting extended lights-out operation. Beyond individual machines, many advanced lights-out manufacturing cells combine multiple machine types with shared robotic material handling and centralized scheduling software, creating fully autonomous production zones capable of continuous automatic production. Within CNC machining centers, horizontal and vertical configurations each have strengths for lights-out operations. HMCs tend to be easier to automate due to tombstone orientation, larger loading areas, and centralized tool storage, supporting higher throughput and smoother robot integration. VMCs can also be automated, though they typically require additional systems such as robots, conveyors, and pallet staging. Choosing between HMCs and VMCs often depends on production volume, part complexity, and the level of automation a manufacturer wants to achieve. Tool Management in Automated Factories Tool management is essential in lights-out factories to ensure consistent production and prevent costly downtime. Machines must regularly check cutting tool inserts for breakage or wear, validate workpiece placement, and ensure spindle or turret accuracy. Without proper monitoring, a single fault can halt production, waste thousands of dollars in material, or damage expensive machinery. Modern automated factories rely on a combination of systems to keep tool management seamless: Massive tool magazines: Store hundreds of cutting tools for automated changes during production runs. Centralized tool storage systems: Track tool life and automatically call up replacements as needed. Probing systems: Mounted on spindles or turrets, these verify workpiece placement and enable in-process measurements to ensure consistent quality. Remote monitoring sensors and software: Alert operators to potential issues, allowing quick intervention and minimizing scrap or machine damage. Human Roles in Automated Factories Even in dark factories or lights-out machining operations, human involvement remains essential for maintenance and management. Skilled operators, engineers, and managers are needed to oversee production, conduct preventive maintenance, troubleshoot issues, and implement process improvements. They also ensure quality assurance and compliance with industry standards, optimizing workflow across the automated factory. In some lights-out manufacturing cells, human intervention may be reduced to weekly or even monthly tasks, such as tool changes or material replenishment. However, fully autonomous factories still require personnel to respond to exceptions, monitor system performance, and maintain the overall health of the production environment. While humans remain central to factory oversight, software and AI increasingly orchestrate the day-to-day operation of these automated cells. Software and Planning for Automated Factories For the most efficient operation of a lights-out factory, manufacturers typically rely on robust software and planning tools to coordinate all aspects of production: Manufacturing execution systems: Track production, manage schedules, and integrate robots with machine tools. Enterprise resource planning: Helps coordinate inventory, supply chain, and overall production planning. Simulation software: Creates digital twins to test workflows and validate processes before physical implementation. AI and machine learning (ML): Can optimize schedules, predict tool wear, and identify defects in real-time. Remote monitoring platforms: Allow supervisors to monitor operations from anywhere via real-time alerts and scheduled analytics reports. Integrating these systems – including AI-driven analytics – enables predictive maintenance, real-time error detection, quality control, and adaptive scheduling. This is essential for smooth, efficient lights-out manufacturing cells. AI in Automated Factories Artificial intelligence is increasingly becoming a cornerstone of automated production. Predictive maintenance algorithms analyze sensor data to forecast potential machine failures, helping prevent costly downtime. AI-driven quality control systems, such as machine vision, can detect defects and adjust processes in real-time, ensuring consistent output. Process optimization applications identify bottlenecks and suggest improvements to throughput, while adaptive scheduling can dynamically adjust production plans to respond to changing demand or equipment availability. By incorporating AI, manufacturers can reduce human intervention while maintaining – or even improving – both quality and efficiency, making fully autonomous production more achievable. Examples of Full Lights-Out Factories Several companies have successfully implemented fully automated factories, showing that lights-out manufacturing is feasible across industries. FANUC (IMTS booth 338900) has operated a lights-out factory since 2001, producing around 50 robots per day, with production running unsupervised for up to 30 days. Meanwhile, Makuta Micro Molding specializes in micro injection molding and produces millions of parts each month with very low defect rates for medical, pharmaceutical, microfluidics, and automotive applications (Makuta). Human intervention is required only to set up machines for each production run. Nomura DS (IMTS booth 338230) offers high-precision turning and milling machines engineered for performance and rigidity; when paired with machine-tending automation like a Load & Go system, the DST series can operate virtually unsupervised (Production Machining). These setups help manufacturers in automotive, fluid power, and medical device industries increase throughput, maintain consistent quality, and free machinists for higher-level tasks – demonstrating how automation can expand lights-out operations beyond fully dedicated robot factories. Royal Products (IMTS booth 431622) specializes in machine tool performance accessories that enable lights-out machining. Its patented Rota-Rack Parts Accumulator allows CNC lathes to run unattended for extended periods, safely collecting finished parts and protecting delicate edges (Canadian Metalworking). With flexible, easy-to-set parameters and universal compatibility across most lathes, the Rota-Rack helps manufacturers increase throughput, reduce labor dependency, and maintain consistent quality, demonstrating practical automation solutions for lights-out operations. Other companies are advancing automation in their facilities as well. Philips runs an almost completely automated factory in the Netherlands producing about 15 million electric razors annually, with human involvement limited to quality assurance. GE Appliances has integrated lights-out operations in its Decatur, Alabama, plant. It uses advanced robotics for metal fabrication and assembly, boosting production consistency and throughput (EU Automation). BMW Group uses lights-out processes for engine component machining (Torka), Schuler Group has robotic press lines capable of continuous operation (Siemens), DMG Mori showcases fully automated production cells at IMTS with integrated robotic material handling and monitoring (DMG Mori), and Trumpf demonstrates automated laser cutting and bending cells requiring minimal human oversight (Trumpf). Bosch has implemented lights-out manufacturing in specific cells at several of its plants, automating assembly, testing, and material handling for high-volume production (Pasha). The Future of Dark Factories The potential of lights-out factories is undeniable. As AI, robotics, and software continue to evolve, more companies may adopt these systems. However, even the most advanced dark factories rely on human expertise. Operators, engineers, and managers remain crucial for programming machines, maintaining equipment, planning production, and optimizing processes. In practice, the factory may go dark, but human oversight continues to guide automated operations. Investment decisions for fully automated factories depend on production volume and predictability, skilled personnel availability, capital capability, and long-term strategic goals such as quality, safety, and competitiveness. For most manufacturers, hybrid approaches combining human oversight with automated systems are the most practical and efficient path forward. Should Your Company Invest in Lights-Out Manufacturing? Automated factories and lights-out manufacturing cells are no longer just concepts – they are operational realities across machining, injection molding, laser cutting, and assembly. Benefits include extended production hours, improved quality, lower labor costs, and safer work environments. But achieving full autonomy requires careful planning, significant capital investment, and skilled human oversight. Even the most advanced dark factories integrate humans for programming, maintenance, and process optimization. For the majority of manufacturers, the most effective approach is incremental: combining automation with human insight to optimize production while minimizing risk. As robotics, AI, and software advance, the factory of the future may increasingly operate in the dark – but human ingenuity will remain the guiding light, ensuring efficiency, quality, and resilience. At IMTS 2026, you can explore lights-out systems live, connect with experts, and find the right solutions for your shop. Begin now: explore dozens of technologies by keyword using the IMTS Search function. And, to see these technologies demonstrated in person, register for IMTS 2026. Read the Automation and Robotics Series What Is Industrial Automation Technology? Robotic End Effector Guide: End of Arm Tooling Types and Trends History of Robotics: Robotic Generations, Coding, and More Autonomous Mobile Robots: Companies, Types, and Advantages Programming Robots Commercial Off-the-Shelf Software for Robotics Sources Canadian Metalworking. (2015, Dec. 15).”Royal Products’ Rota-Rack for Lights Out Manufacturing.” Accessed September 6, 2025, from https://www.canadianmetalworking.com/canadianmetalworking/product/metalworking/royal-products-rota-rack-for-lights-out-manufacturing. DMG MORI. (2023, March 23). “Spot On for the Lights-Out-Factory.” Accessed September 6, 2025, from https://uk.dmgmori.com/news-and-media/blog-and-stories/blog/what-is-lights-out-manufacturing. EU Automation. (n.d.). “Lights-Out Manufacturing: How Bright Is the Future?” Accessed September 6, 2025, from https://www.euautomation.com/en/knowledge-hub/read/blogs/how-bright-is-the-future-of-automation. Lux Research. (n.d.). “Lights-Out Manufacturing: Still a Moonshot or a Closer Reality?” Accessed September 6, 2025, from https://luxresearchinc.com/blog/lights-out-manufacturing-still-a-moonshot-or-a-closer-reality/. Makuta. (n.d.). “Lights-Out Micro Injection Molding.” Accessed September 6, 2025, from https://makuta.com/lights-out-micro-injection-molding/. Pasha, Abdulla. (2024, Sept.). “Lights Out Manufacturing: Revolutionizing the Factory Floor with Automation.” Bosch SDS. Accessed September 6, 2025, from https://bosch-sds.com/wp-content/uploads/2024/09/Lights-Out-Manufacturing_-Revolutionizing-the-Factory-Floor-with-Automation.pdf. PR Newswire. (2021, Sep 23). “Global Lights Out Manufacturing Market Report 2021.” Accessed September 6, 2025, from https://www.prnewswire.com/news-releases/global-lights-out-manufacturing-market-report-2021-top-nine-technologies-companies-must-consider-switching-to-a-lights-out-manufacturing-environment-301384118.html. Production Machining. (2024, Nov. 5). “Nomura DS Showcases Turning and Milling Machines Engineered with Excellence.” Accessed September 6, 2025, from https://www.productionmachining.com/articles/nomura-ds-showcases-turning-and-milling-machines-engineered-with-excellence. Siemens. “Industrial Edge Turns Press Shop Into Smart Factory.” (n.d.) Accessed September 6, 2025, from https://www.siemens.com/global/en/company/stories/industry/factory-automation/schuler-pressen-gmbh-machine-building-industrial-edge-germany.html. Torka, Benedikt. (2024, Nov. 25). “High-Tech in Production: BMW Group Enables Automated Driving for New Vehicles.” BMW Group Press. Accessed September 6, 2025, from https://www.press.bmwgroup.com/global/article/detail/T0446493EN/high-tech-in-production:-bmw-group-enables-automated-driving-for-new-vehicles. Trumpf. (n.d.). “Automating bending operations relieves the burden on personnel.” Retrieved September 6, 2025, from https://www.trumpf.com/en_GB/newsroom/stories/automation-in-bending-saves-time/.
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