From Manual to Lights-Out: A Tending Roadmap

“Lights-out” automation — running unmanned shifts — is no longer reserved for OEM giants. With cobots, modular tooling, and smart scheduling, even small manufacturers can build an incremental path to 24/7 tending without breaking budgets or safety rules.

Step 1: Semi-Automation

• Start by automating load/unload while keeping manual part inspection.
• Use quick-change trays and teach simple repeat jobs first.
• Monitor OEE and downtime to build the business case for full automation.

Step 2: Extended Unattended Runs

• Add vision checks and pallet staging for overnight operation.
• Integrate sensors for chuck verification and door feedback.
• Use SMS or app alerts for operator intervention when needed.

Step 3: True Lights-Out

• Implement redundant grippers and tool monitoring to handle exceptions.
• Integrate machine condition monitoring and automatic tool offset correction.
• Log all cycle data for traceability and quality assurance.

Case Study

A precision machining SME moved from 8-hour shifts to 24/7 lights-out operation in 14 months using cobots, tray handling, and predictive maintenance alerts. ROI: under 11 months.

Related Articles

• High-Mix, Low-Volume Machine Tending with Cobots
• Tending CNCs Safely: Doors, Interlocks, and Guarding
• Cycle Time Math: How to Hit Your Takt with Cobots

Conclusion

Lights-out doesn’t happen overnight. But with a structured roadmap, cobots make it achievable — turning idle hours into productive, safe, and profitable time.