Automation

    lights out manufacturing

    What is ‘Lights Out’ Manufacturing?

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    “Lights out” manufacturing is a fully automated process. It literally means that the production process continues with the lights out, with no human participation.  “Lights out” is also a description of an automation-based philosophy of manufacturing.

    The name is slightly misleading, in both cases. Operationally, many factories operate automatically, but to various degrees during the “lights out” process. Handling, maintenance and production oversight by humans are still required for safe operation. From the philosophical perspective, human management is also part of the process.

     

    The Theory of “Lights Out” Manufacturing

    The idea of fully automated manufacturing is based on lower operating costs, higher production speeds and reducing manpower costs. It’s actually a business theory, as much as a manufacturing theory.

    The theory also works in practice. Current levels of automation don’t really need a lot of human participation in many cases. Projected future automation will probably need even less human involvement.

    This type of manufacturing is stringently costed to deliver a series of cost efficiencies at all levels of operation. The metrics used are core business costings, based on unit price, materials, labour, and other conventional measures. An entire production run of a product can be accurately costed, virtually to the last dollar.

    The Practice of “Lights Out” Manufacturing

    The theory, however, comes with multiple caveats in practice. If process handling is becoming obsolete, other types of human participation are essential.

    Human operations may be required for:

    • Quality control
    • Emergency and routine maintenance
    • Systems installation, retooling and upgrades
    • Systems management, including electrical, plumbing, and communications
    • Monitoring production and processing systems
    • Production planning and coordination
    • New product production implementation
    • Management

    In theory, “lights out” manufacturing can operate indefinitely and efficiently. The problem is that production errors, changes in products, breakdowns, and system issues are inevitable.  Humans must be on site to manage these issues.

    The Dashboard Effect

    One of the most important functional efficiencies in this type of manufacturing is the ability to accurately monitor operations in real time. The “dashboard effect” is the real time reporting capacity of digital systems using dashboard software to monitor businesses. In industry, there are many variations on this theme, including remote monitoring of sites by management and operations staff. It’s easy to get a report or access your dashboard with your phone, for example.

    These dashboard systems are good hands-on assets for managers. These systems also provide “operational audits”, like batch information, figures, times and dates for operations.  A “lights out” system can deliver lots of high value information for business uses, which can then be integrated with other business systems like sales and marketing. The net effect is a fully traceable range of metrics from production to sale.

    Need Help With a “Lights Out” Operation?

    EPG Electrical Plumbing Group Pty. Ltd.  is a full service consultancy and onsite services provider for factory automation in Brisbane. We offer services for plant and site switchboards, and also electrical and plumbing contractor services. To enquire about our services, call us on (07) 3319 5068 or if you prefer, contact us online.

    Australia’s Manufacturing Evolution: A Case Study

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    The history of manufacturing in Australia is a strange tale of national perspectives, local and global economics. In early colonial days, manufacturing, such as it was, was mainly consumables. The rise of the agricultural export industries added some acceleration, producing locally needed goods. During the Gold Rush of the 1850s, the demand for gold mining equipment jump-started basic manufacturing of tools and equipment. Public works, infrastructure and the new railway systems added a heavy industry component, based largely on local demand.

    By 1891, industrial manufacturing accounted for 4.9% of GDP and 149,000 jobs in all industries. (Figures: Australian Bureau of Statistics 22 November 2012.) Federation in 1901 and free trade between the states generated a total of 328,000 jobs by 1913. (ABS figures as above.)

    Australian Manufacturing in the 20th Century

    World War 1, the emergence of the steel industry, growing wool and wheat markets, and “expansionist” policies helped drive industrialisation in Australia until the Depression in 1929. Even the Depression, however, barely dented progress in manufacturing. The expanding economy now included motor vehicle manufacturing, cement, rubber, engineering, and electrical manufacturing industries.

    During World War 2, manufacturing overtook agriculture as the leading component of Australian GDP. The nation’s industries were adequate to support war needs. After World War 2, protectionist tariff policies and a booming population growth supported further growth and expansion through the 1960s and early 1970s. The 1970s mining boom and oil exploration successes added further expansion to Australian industry growth.

    The Big Decline

    Australia’s bad habits of relying on protectionism and commodities came fully unstuck in the 1980s. As early globalisation and new global economic factors, notably inflation, took hold, Australia’s terms of trade and the economic viability of the old systems of manufacturing suddenly eroded.  Protectionism also ended, and cheaper imports decimated Australia’s old made-under-license consumer products manufacturing sector.

    The Early 21st Century, New Opportunities, and New Growth

    A roller coaster ride of global prices and market moves followed through the 1990s and turn of the century. Australia’s mining boom held up the manufacturing sector to some degree, but the old business models were out of sync with the global market. Manufacturing was hit by a colossal double whammy of global production and fluctuating prices for which it simply wasn’t prepared or structured to manage.

    The Lucky Country, however, has also had some new, high-value luck in manufacturing. Australia’s old model manufacturing was about to hit its expiry date, anyway. New manufacturing techniques, automation, 3D technology, new materials science, and innovation in a progressively scientific and industrial setting are opening up a vast range of new opportunities.

    The future of Australian manufacturing is looking a lot better than in the recent past, with a lot of realistically attainable upsides. A new competitive and market-oriented mindset is another major plus, free of the rather unimaginative, insular local perspectives of the past.

    Building a New Australian Manufacturing Sector

    If you’re looking for new manufacturing solutions, EPG Electrical Plumbing Group Pty. Ltd. offers a full suite of consultancy and advanced factory automation services for manufacturers in Brisbane. Our services also include plant and sites switchboard, as well as electrical and plumbing contractors. Call us on (07) 3319 5068 or contact us online to discuss your business needs.

    The Future of Factory Automation

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    Automation is one of the most controversial subjects in any discussion of the future of industry and society as a whole. Some people worry that automation will simply take jobs, without replacing them. Others say that automation is more efficient, more flexible, and inevitable economically.

    The Current Realities of Factory Automation

    Factory automation is at the centre of these arguments. Traditionally, factory production is both a major employer, and the defining reality of manufacturing at all levels. Despite the many arguments, the future of factory automation is likely to be based on pure economic realities.

    The current reality is that partial automation is already a fact of life in most industries. New technologies, new automated systems, new system designs, and materials are progressively phasing out old-style manufacturing. Studies have shown that automated production is cheaper, quicker, and produces direct cost benefits for consumers.

    Future Factory Automation

    The next stage of future factory automation is already happening in China, where whole factories are being turned over from manpower to pure automation. This is also a form of “lights out” manufacturing. This type of manufacturing is 24/7 production without much human participation in the actual manufacturing process.

    Another critical economic factor in future factory automation is the sheer flexibility of this type of production. A fully automated factory can switch from producing one product to another almost instantly. The economic values of this capacity are that a single automated factory has the equivalent production of several old-style factories.

    New options for manufacturing, like large-scale high speed 3D printing, are currently under development. This new manufacturing technology can manufacture any kind of product, from toys to advanced components for spacecraft.

    Whole industries could benefit from these highly agile production capabilities.  A 3D printer-based factory can print an entire house, which has already been done in China. A mansion can be printed in 45 days.

    Another 3D printing process printed 10 houses in 24 hours. Custom designed 3D printed houses could be created using CAD programs with literally millions of design choices. You can’t really argue with that level of economic efficiency, particularly when cost benefits delivered those houses at a fraction of conventional construction costs.

    Factory Automation and Future Jobs

    Manufacturing on this scale also creates jobs in high-end employment fields like:

    • Industrial process systems
    • Product designers
    • Engineering
    • Electrical
    • Plumbing
    • IT designers
    • Software
    • Sales and marketing
    • Retail
    • Online businesses
    • Wholesalers and distributors
    • Communications
    • System technicians like plumbing and electrical

    Everybody will see many direct positive effects of automation. This type of manufacturing delivers a “whole economy” effect. It’s already happening around the world. The fact is that factory automation is based on market needs, which naturally and reliably reflect social needs. The entire global supply chain, from production to consumer, will benefit from these manufacturing techniques, and so will humanity.

    Need Some Help with Your Factory Automation and Systems?

    EPG Electrical Plumbing Group Pty. Ltd. is your full bandwidth solution for industrial automation and onsite systems needs. Our services include factory automation, switchboards, commercial electrical contractors and plumbing services. We also provide related consultancy and planning services for factories in Brisbane. Contact us by phone or use our online form to get in touch and one of our team will respond to your enquiry ASAP.