Lights-Out Manufacturing: The Future of 24/7 Production is Already Here

Imagine a factory that never sleeps, machines humming quietly through the night, robots transporting materials without human intervention, and every system perfectly in sync, all while you manage it remotely from your laptop or smartphone. Sounds futuristic? Not anymore.

Welcome to the world of lights-out manufacturing, where automation, robotics, and intelligent orchestration are making the dream of 24/7, human-free production a fast-growing reality.

From Sci-Fi to Shop Floor: What Is Lights-Out Manufacturing?

The term “lights-out” literally refers to factories running in the dark because they don’t need people inside to function. Machines, robots, and AI-driven systems handle production, logistics, quality checks, and even maintenance.

It may sound like something out of a sci-fi movie, but companies like FANUC and Xiaomi are already running fully automated facilities, some operating for 30 days straight without human presence.

A 4-Step Evolution (According to ITI Group)

Global integrators have outlined a clear roadmap:

1. Connected systems (data visibility)

2. Semi-autonomous cells (robotic assistance)

3. Integrated orchestration (remote monitoring and control)

4. Fully autonomous facilities (lights-out)

Each step builds toward a smarter, leaner, and more reliable production system. And it’s not just about robots, it’s about how everything works together.

Robots That Work While You Rest

One of the most exciting enablers of this shift is the rise of Autonomous Mobile Robots (AMRs). These intelligent machines don’t just move materials, they learn paths, avoid obstacles, and make decisions in real time. According to Innorobix, AMRs are critical for 24/7 shifts, especially in warehousing and manufacturing setups aiming for minimal human intervention.

And thanks to recent advances in machine vision and AI, robots are no longer blind or dumb; they see, adapt, and even retrain themselves when conditions change.

The Unsung Heroes: Software and Maintenance

Of course, robots can’t run on hardware alone. Computerised Maintenance Management Systems (CMMS) and orchestration software (like MES and SCADA systems) are quietly doing the heavy lifting, monitoring performance, predicting breakdowns, and assigning tasks across the floor.

Platforms like MAPCON’s CMMS are enabling predictive maintenance, which means machines can tell you when they need attention, before anything breaks.

And in this ecosystem, data is king. The more your systems talk to each other, the smarter your operation becomes.

Governments Are Taking Notice

Globally, countries like Japan, Singapore, and Germany are investing in automation hubs and incentivising “super-factories.” A recent report by ITIF highlights how policymakers are embracing automation as a key to competitiveness, while also retraining workforces to take on higher-order, supervisory roles.

But How Close Are We Really?

We’re not quite at the point where every factory is dark and deserted. But according to Control Design’s June 2025 feature, industries like semiconductors, electronics, and automotive are very close. Low-code programming tools, real-time orchestration platforms, and even AI copilots for robot programming are breaking down the last few barriers.

What About South Africa?

Here in South Africa, the idea of lights-out manufacturing might seem like a far-off ideal, but we’re already seeing the foundations. Many local manufacturers are:

• Investing in smart PLCs and SCADA systems,

• Deploying collaborative robots (cobots),

• Experimenting with predictive maintenance, and

• Looking into 24/7 energy and load balancing solutions (especially relevant in a power-sensitive market).

The beauty of lights-out is that you don’t have to jump straight to full automation. South African companies can start small, a single automated cell, an AMR pilot, or a remote monitoring dashboard and scale up over time.

In fact, with the growing availability of local system integrators, robotic automation vendors, and a push toward smart manufacturing incentives, South Africa is in a prime position to leapfrog traditional factory models and go straight into modular, efficient, and adaptive production systems.

A Shift Worth Watching

Lights-out manufacturing is more than a trend; it’s a strategy for resilience, productivity, and long-term competitiveness. While global players are already building autonomous factories, South Africa doesn’t have to be left behind.

The question is no longer “Is this the future?”It’s “How can we make it work for us today?”

---