Lights-out manufacturing: The next phase of digital manufacturing maturity

What is lights-out manufacturing?

Lights-out manufacturing refers to factories that are almost entirely operated by automated machines, robots and connected systems with minimal human intervention. Also known as dark factories (because robots can work without lights), these facilities can operate round-the-clock, with automated machines handling activities from production and inspection through to decision-making.

Lights-out manufacturing isn’t about replacing people with machines or achieving a robotic end-state, but it does represent the current end-state of digital maturity in manufacturing, where connected systems, autonomous decision-making and trusted data make increasingly autonomous operations possible.

While fully lights-out operations may still seem like a distant goal for some manufacturers, many organisations are already building the digital foundations that make future autonomy possible.

Where is lights-out manufacturing already being used?

While fully autonomous factories are still relatively uncommon, several manufacturers are already demonstrating what lights-out operations can achieve. Here are three real-world examples of lights-out manufacturing in practice.

1. FANUC (Japan)

Japanese robotics manufacturer FANUC is one of the best-known examples of lights-out manufacturing. Its highly automated manufacturing operations have used robots to manufacture other robots, with some production capable of operating unattended for.

2. Philips (Drachten, Netherlands)

Philips’ Drachten facility is another frequently cited example. However, people remain involved in quality assurance, illustrating an important point: lights-out manufacturing doesn’t necessarily mean removing humans entirely.

3. Xiaomi Smart Factory (Changping, Beijing)

Xiaomi’s smart factory in Beijing has demonstrated how the concept of lights-out manufacturing is evolving. Its smartphone manufacturing operation uses and is designed for continuous production with minimal human involvement.

The vision: Why manufacturers are pursuing lights-out factories

Manufacturers face growing pressure to deliver more for less. Customers expect speed, quality and traceability, while costs continue to rise and supply chains remain volatile amidst geopolitical tensions. Increasing regulatory requirements and evolving environmental targets are also pushing manufacturers towards low-waste, energy-efficient operations.

Added to these pressures are ongoing labour shortages and a growing skills gap, propelling the industry towards a digital shift that could have a significant impact on efficiency. McKinsey, productivity and throughput could increase by up to 30% through advanced automation.

The reality of lights-out operations

A common misconception is that lights-out manufacturing means a completely human-free factory. In reality, even highly automated facilities still require:

• Maintenance engineers
• Reliability and automation specialists
• Centralised monitoring
• Human intervention during changeovers, major faults and continuous improvement activities

In practice, selective lights-out processes are far more achievable and economically viable than a fully autonomous factory.

Why most manufacturers aren’t ready for lights-out operations

While lights-out manufacturing will fundamentally reshape the industry, the shift can’t happen overnight. Most manufacturers simply aren’t ready.

Data remains one of the most critical barriers to digital maturity. Many manufacturers still struggle with data silos and inconsistent master data, a foundational issue that’s often overlooked during transformation. Disconnected legacy systems compound the issue. Systems don’t communicate, manual workarounds create friction, and real-time operational insight is limited. In this environment, autonomous decision-making becomes difficult.

Upfront cost is also a significant barrier and one of the reasons many manufacturers will never achieve a fully lights-out state. Becoming fully automated doesn’t just mean implementing expensive new technologies; it means reviewing processes and refining workflows, gaining stakeholder buy-in and facilitating ongoing change management, often in partnership with experts.

But cost doesn’t need to halt progress. Modern manufacturers are already taking a strategic, incremental approach that focuses on building the connected digital foundations required for increasingly autonomous operations. Whether they intend to pursue a fully lights-out state or not, having these foundations in place gives manufacturers the potential to scale, grow and adapt as the industry evolves.

Creating the digital foundations for autonomous operations

Manufacturers who want to stay competitive may not see lights-out operations in their immediate future, but they should view it as part of their long-term operational intelligence strategy.

For most manufacturers, the realistic journey is:

1. Predictive maintenance
2. Automated quality inspection
3. Autonomous material movement (AGVs/AMRs)
4. MES-driven production control
5. Closed-loop scheduling and optimisation
6. Selected lights-out cells or production lines
7. Lights-out plants for highly repetitive product families

This incremental approach is considerably more achievable and delivers a better ROI than attempting to build a dark factory from day one.

One of the critical steps for manufacturers pursuing any level of automation is to connect their data across ERP, MES, shop floor systems, IoT systems, maintenance platforms, supply chain data, AI and analytics. This integrated infrastructure forms the backbone of lights-out operations, collecting, storing and sharing the real-time data that enables autonomous decision-making.

With connected systems in place, manufacturers can begin introducing semi-autonomous cells and integrating automation, marking the first steps towards lights-out production.

Automation to autonomy with Columbus

At Columbus, we help manufacturers move from automation to autonomy. Get in touch via the contact card below to discuss how we can support your organisation’s digital transformation and take the next steps towards lights-out operations.