11/8/2023 0 Comments Lights out manufacturing![]() ![]() The company’s report, “The Path to Lights-Out Manufacturing,” explores the road map for automating different types of manufacturing tasks, including the robotics technologies involved the main drivers and barriers for automation and a lights-out manufacturing timeline for different manufacturing tasks. The organizations that find ways to marry augmentation and automation-to build workflows that improve human performance-will be best poised for what comes next.As more tasks become automated across manufacturing, these environments will rely less and less upon manual human labour, with the goal of lights-out manufacturing.Īchieving lights-out manufacturing is a major goal for many companies, but it might not be realistic because of significant barriers and a prolonged timeline, according to new analysis from Lux Research, a technology research and innovation advisory service. But as we’ve reviewed here, there’s a better way. Historically, organizations have responded to crises by using automation to replace human labor. A view that recognizes humans as essential, and works from there. Throughout this post I’ve argued that manufacturers should adopt a more optimistic view of human potential. Eliminate bad tasks, enable workers to do more, and evolve what manufacturing work looks like. Instead of thinking of automation as either or, think of automation as a way of augmenting human performance. This mantra can help us think our way out of the lights out factory dilemma. The critical factor here is to think about how humans fit into those processes, and how workflows can be redesigned to enhance human performance. So instead of adding robots to make old processes more efficient, manufacturers should reimagine how they create their products. In the last few years, leading analysts have asked manufacturers to rethink their processes. Is it data collection? A manual process? Where and how are workers involved? Is what looks like one task actually a collection of many tasks? Will introducing automation improve worker safety? Answering these question will help you understand the nature of human engagement, and move you closer to a solution that works. When you’re looking at replacing a task with a robot or software, think about what it is, exactly that you’re automating. Understand the tasks you want to automate Here are some things any manufacturer assessing automation should consider. The goal should be to empower workers, to change the way they work rather than changing the fact of work. Rather, manufacturers will do better by automating the parts of manufacturing work that contribute to human error. Past attempts at lights out factories have shown us that it’s a mistake to engineer humans out of the factory. In other words, manufacturers should focus on “lights out processes, not lights out factories.” Things to Consider Before Turning the Lights Off We need to help humans do what they do best, and let automation rule on repetitive, tedious tasks. This observation is key to getting automation right. As much as 70% of human errors are really attributed to “organizational weaknesses.” In other words, humans make mistakes because complex or badly designed workflows set them up to fail. In a summary of years of research into human performance, system design, and workplace errors, the United States Department of Energy came to a surprising conclusion. We all know the cliche “to err is human.” What the pessimistic perspective on human performance gets wrong is that most human error isn’t attributable to mistakes. This haven’t proven to be the case, and here’s why. The problem is that the move to eliminate human labor entirely is based on a faulty assumption: if automation is more efficient and less error-prone than humans, then more automation will lead to greater efficiency. As one analyst recently put it, “let’s face it: for some companies removing paper or eliminating a manual process would be a revelation.” The problem with lights out factories was never with the idea that some work should be automated. ![]() ![]() The key to getting automation right? Evolve how we work. Previous attempts at turning the lights off have all found that human flexibility is the best match for manufacturing’s complexity. Even manufacturing luminaries like AppleĪAPL have found that it’s hard to match human flexibility and precision. The engineering required to build fully automated lines is staggering and, if they break, diagnosing and solving the problem is an equally difficult task. Modern manufacturing lines can require decision making and sensitivity that’s hard to replicate with algorithms and robots. In reality, manual assembly requires an enormous amount of individual skill. There’s a misperception that manufacturing work is dull and repetitive. 1.) manufacturing work is complex, and 2.) automation is inflexible. ![]()
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