What's the Lowdown on 'Lights Out'?

1) Process must be high statistical capability and in statistical control;

2) Machine tools must be equipped with fire detection and suppression equipment

3) Parts takeoff process must allow for sequential identification so verification of variables attributes can be determined and parts segregated if found to be out compliance.

4) Attention to tool condition is mandatory. Usually some broken tool detection is in place.

5) Typically machines run until bar feeder runs out, not necessarily "all night."

A number of PMPA shops continue to successfully operate in this manner to increase throughput. Their craftsmen-machinists support this means of keeping us precision machining competitive and sustaining manufacturing jobs.

Ain't no skilled machinists feeling superfluous in shops today.

Milo

We have computerized punch presses at work with sheet loaders and vacuum parts unloaders. Before leaving work they load up a program and let the maching run unattended. Day shift comes in finds a 4 X 10 sheet wrapped up in the clamps and a couple of parts broken. Day and several new parts later the machine is back running.

No running unattended after the big bite in the rear. Then a few weeks later they are back at it until WHAM.....more expensive parts and more downtime.

Lost production could cost thousands of dollars and lost contracts.

A friend and I had a small manufacturing plant that cut, bent, welded & stacked wire parts. It had sensors on every step, time windows for every move and every possible fault covered. The compressed air was matched to the usage, the welder matched to the load and each bit of compressed air reused multiple times.

For 10 years we ran the machine overnight and unattended. If it stopped a phone dialler rang one of us up to come in (if needed). No workers, no unions, no health and safety problems, no complaints about the dingy work area.

Run time 16hrs/day, 7 days a week, Our time 15min/day to load a new pallet. Effective hourly rate 600$/hour. Nice. "Lights out" manufacturing has a lot going for it. Ffej

Andrew Carnegie said "the key to wealth is to figure out how to make money while you sleep". That is certainly true and the next question is is what systems can be put in place to make that happen?

Like Milo mentioned there are many factors to consider about supplies, mechanical issues etc. The good thing is that there is good technological support for the monitoring process and by sending ALARMS to smart phones, pagers etc. to on-call personnel. The monitoring is only as good as the equipment design or if during manual operation as good as the people who are on the floor monitoring the equipment as it operates.

There is always risk involved in any process that is balanced with the potential benefit. If the human element can be removed to a certain extent there is great advantage, especially with the potential increase of employee costs due to governmental harassment in the form of increased taxes, regulation, health care etc.

The purpose of a business is to make money, not to provide an income for people. The income for people is a side plus for those people who end up having a job made available because someone was willing to take risk, invest capital etc. However it is possible to make the business work is on the table, automated or not. Ownership also needs to recognize that people are a necessary component of their operation and treat them properly in order to maintain a smooth running operation.

Sounds like you need some new people who will take ownership of what they are responsible for, or a system that will replace their lazy butts.

Let's carry automation to the extreme:100 % automation of all processes, no people required to produce a product.Question is,who can buy the product if they are unemployed?

A select few will be required for maintenance,but fewer and fewer as technology progresses,and intelligent machines will be able to provide diagnostics and instructions to a minimally skilled technician,perhaps with a contact lens or retinal implant display of machine components and visual/audible instructions on how to repair.

What type of economy will exist with hardly any workers/buyers?

It may indeed be lights out in more ways than one.

We can continue to warehouse the nonworkers (criminals) in prisons.

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