ccording to Intelligence Industrielle, by 2030, 35% of large manufacturing companies will have fully autonomous
facilities, or ‘lights-out manufacturing’. This refers to production environments that operate around the clock by relying on automated and other Industry 4.0 technologies to assemble parts, manage assembly lines, perform inspections and handle logistics. Last September, the World Economic Forum
welcomed twelve new members into its Global Lighthouse Network, bringing total membership to 201 facilities across multiple industry sectors. Facilities are chosen to join this based on their use of Industry 4.0 technologies – automation, robotics, AI, digital twins and data-driven production systems – to drive measurable improvements in their productivity, sustainability and innovation. Lights-out manufacturing is among the most ambitious practices explored in some Lighthouse sites. However, while fully unmanned production is
even uncommon within the Lighthouse Network, the success of an electronics manufacturing service leader in Vietnam and semiconductor manufacturer in Shanghai demonstrates that lights-out production is possible.
With lights-out manufacturing, factories can operate around the clock, increasing productivity by around 30%, whilst reducing product defects by approximately 40% and minimising risks to personnel. Furthermore, through intelligent management of lighting, heating and ventilation, energy consumption can also be optimised. However, many sites still use legacy equipment that was never designed to integrate with modern automation or digital systems. Robotic arms, conveyors, CNC machines, and autonomous guided vehicles are commonplace in facilities that utilise automated technologies. The expectation to continually operate, unsupervised, while maintaining consistent precision, efficiency and reliability, places considerable strain on these
machines. In a lights-out environment, the smallest fault in one system has the potential to ripple across a production line, disrupting logistics, compromising product quality or halting operations altogether. So, what’s the solution?
Only when components are engineered for reliability, precision and efficiency can lights- out systems operate as intended. Motors are one of the most important
components in automated technologies, providing the motion, control and accuracy required. During continuous, unsupervised lights-out manufacturing, their significance increases, as they must deliver long-term durability, consistent repeatability and the high efficiency required to enable reliable, autonomous production. Stepper motors, for example, move in fixed
micro-increments, providing highly accurate positional control. Advanced stepper designs,
such as FAULHABER’s AM3248 series, are compact solutions, capable of the high torque necessary for demanding applications. With 1.8-degree step angles and micro-
stepping options, these motors provide fine positional resolution and smooth motion control. Their low inertia and minimal detent torque enable rapid acceleration and deceleration, while maintaining repeatability critical for tasks such as pick-and-place assembly or inspection systems. By delivering consistent and reliable motion, these motors ensure that automated equipment can perform reliably with minimal human input, safeguarding production output and quality. In contrast, brushless DC motors offer a
long service life, high efficiency, and smooth operation. As they use electronic commutation instead of mechanical brushes, wear and maintenance demands are reduced. In a lights-out environment, this becomes particularly important. For example, AGVs navigating factory floors or conveyor systems transporting parts must run continuously, often around the clock. Brushless motors support this by
delivering high efficiency and
long-term durability, minimising unplanned downtime and helping manufacturers control operating costs.
Their low vibration also helps to improve accuracy in delicate processes, such as those carried out by inspection equipment and CNC machining. As manufacturing moves toward greater
autonomy, the capabilities embedded in each component will define what is possible. Advanced motors, engineered for precision, durability and efficiency, are enablers of the lights-out future.
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