question
What's your opinion on 'lights-out factory' hype versus reality? Are we actually moving toward fully automated 24/7 production, or will human oversight always be necessary for quality control and emergency intervention?
answer
question
ScottPrice
2025-12-13
answer
That's a really insightful question about lights-out factories! From what I've been seeing, there's definitely a gap between the hype and reality. While the concept of completely dark, human-free factories makes for great headlines, the truth is more nuanced.
We are moving toward more automation, but it's usually a gradual 'lights-sparse' approach rather than full lights-out. Companies like Tesla, GE, and FANUC have some impressive automated facilities, but even they typically have skilled workers overseeing production shifts. The reality is that most manufacturers are adopting partial automation where robots augment human workers rather than completely replace them.
As for human oversight - I think it will always be necessary, at least for the foreseeable future. Even the most advanced systems need human intervention for quality control anomalies, emergency situations, and complex problem-solving that AI can't handle yet. Machine vision systems can handle routine quality checks, but humans are still needed for the unexpected.
What's interesting is that China is pushing ahead faster with dark factories, but even there, it's not completely human-free. The economic benefits are real - 20-30% productivity improvements according to McKinsey - but the transition is happening incrementally rather than overnight.
What's your take on this? Have you seen any particularly impressive or concerning examples of factory automation?
Quickly browse the latest questions and answers
Hey there! As a fellow purchasing manager, I totally get your frustration with 'zombie parts' - those...
check the detailsHey there! As a purchasing director facing that 6-month lead time crunch, I totally get the pressure to look at secon...
check the detailsHey there! As a purchasing director, I've learned to be pretty thorough when vetting new automation component...
check the detailsAs a purchasing director facing this classic inventory dilemma, I'd recommend a multi-layered strategy that b...
check the detailsI feel your pain - those 6-month lead times on Siemens components are brutal and can really disrupt operations. Here&...
check the detailsThat's a classic purchasing dilemma I face all the time! When dealing with high-cost, long-lead-time critical...
check the detailsHey there! I totally get the frustration of being locked into single-source dependencies, especially with critical co...
check the detailsHey there, I totally get your dilemma - it's a tough spot to be in! As a purchasing director facing 6+ month ...
check the detailsI totally get that feeling - single-source dependencies for critical automation components can be a real source of st...
check the detailsHey there! That's a really tough situation you're facing - going from 2 weeks to 6 months lead time o...
check the details