Embracing Ecosystems: Issue #12

Author: Marco van Veen

Achieving Lights Out Manufacturing through a Collaborative Ecosystem Approach

Introduction

Lights out manufacturing, where factories operate autonomously without human intervention, represents the pinnacle of industrial automation. Achieving this ambitious goal requires a collaborative ecosystem approach, integrating various stakeholders and technologies. Achieving lights-out manufacturing depends on a robust collaborative ecosystem, where diverse stakeholders and technologies integrate to ensure seamless operation. This article explores how such an ecosystem can be developed, focusing on key elements like different ecosystem phases, predictive examples, technology and service suppliers, workforce optimization, circular economy, open industry alliances and new business models.

What ecosystem is needed to apply ‘Lights out Manufacturing’?

A robust ecosystem is fundamental to lights out manufacturing. The Design, Build, Operate, and Maintain phases are only successful through collaboration between EPCs, technology suppliers, service providers, OEMs, and end-users, ensuring continuous improvements. So, it’s more about collaboration and partnerships to drive performance improvement instead of creating competition by annual tendering and trying to achieve price reductions. By leveraging data and IoT, these stakeholders can share data and insights, enabling real-time monitoring and optimization of manufacturing processes.

One example ...From Reactive to Predictive Maintenance

Let’s take the Maintain phase. Transitioning from reactive to predictive maintenance is crucial for minimizing downtime and maximizing efficiency. Predictive maintenance is powered by the ecosystem’s collaborative efforts, where shared data from technology suppliers and service providers enables real-time monitoring and process optimization.

It uses advanced analytics & diagnostics and machine learning from ‘sensors’ to anticipate equipment failures before they occur. Typical diagnostics according to NE107 standard is explained by Alexander Franke in this video. ?This proactive approach reduces unexpected breakdowns, extends equipment life, and ensures continuous production, which is essential for lights out manufacturing. It also requires a total different work process based on relevant data, new AI tooling and instant decision making. Talking about data; See how David Wallace elaborates the Value of Data in this article in BioPhorum

Typical ‘new roles’ in this new way of manufacturing

Since ‘data’ will be used for a lot for decision making, Data Scientists and Analysts will be needed to analyse data from various sources to optimize processes and predict maintenance needs. They are typically skilled in data analysis, machine learning, and statistical modelling.

Further, since many sources in such a facility will be ‘connected’ and can consist of sensitive data, a secure cyber strategy is required and to be managed by IT and Cybersecurity Specialists. They Ensure the security and reliability of the facility’s IT infrastructure. It is their skill to have the expertise in network security, data protection, and IT systems management.

Talking about people...the challenges around workforce reduction and how to optimize...

It is an increasing struggle globally to find qualified workforce in the manufacturing space. While lights out manufacturing aims to reduce the need for human intervention, it does not eliminate the workforce entirely. Instead, it shifts the focus from manual Labor to more strategic roles, such as overseeing automated systems and analysing data as mentioned earlier. This transition requires reskilling and upskilling the workforce to adapt to new technologies and processes.

How to comply with drivers which focus on Circular Economy and Sustainability?

Integrating circular economy principles into lights out manufacturing promotes sustainability. This approach emphasizes the reuse, recycling, and repurposing of materials, reducing waste and environmental impact. By designing products and processes with sustainability in mind, manufacturers can achieve both economic and environmental benefits.

So why are Technology Suppliers making a difference here?

Technology suppliers play a pivotal role by providing the necessary hardware and software solutions. These include robotics, AI, machine learning, and IoT devices that enable automation and data-driven decision-making. Some are delivering the physical Eyes and Ears of the process... aka Measurement Instrumentation or sensors. These devices deliver key data which goes beyond the Process Value... Think about Safety, Logistical, Energy or Maintenance data. From all those devices, corresponding ‘Digital Twins’ will support the ecosystem dramatically.? Please find some Use Cases at Use Cases - IDTA (industrialdigitaltwin.org). Collaboration between technology suppliers and manufacturers ensures that the latest innovations are effectively integrated into the production process.

What level of support deliver Service Suppliers and OEMs?

Service suppliers offer essential support, from installation and maintenance to training and consulting. Many Technology suppliers nowadays also deliver these type of service levels as a combined offering. Their expertise ensures that the technology is correctly implemented and maintained, allowing manufacturers to focus on production. By working closely with OEMs, service suppliers help create a cohesive and efficient manufacturing environment. In many ways it is still a ‘people ecosystem’.

Original Equipment Manufacturers (OEMs) are at the heart of the manufacturing ecosystem. They design and produce the machinery and equipment used in production. By collaborating with technology and service suppliers, OEMs can ensure their equipment is compatible with the latest automation technologies, facilitating the transition to lights out manufacturing.

Ecosystem collaboration driven by an Open Industry Alliances

An open industry alliance fosters collaboration and innovation by bringing together various stakeholders, including manufacturers, technology suppliers, service providers, and research institutions. This alliance promotes the sharing of knowledge, best practices, and standards, accelerating the development and adoption of lights out manufacturing technologies. See how openindustry4.com works together in an ecosystem combined with Technology suppliers, OEMs and end-users. How we work (openindustry4.com). Open industry alliances form the backbone of the lights-out manufacturing ecosystem, driving innovation, knowledge sharing, and standardization across all players.

What Business Models are applied?

Lights out manufacturing enables the creation of new business models. For example, manufacturers can offer production or energy -as-a-service, where customers pay for the output rather than the equipment. This model provides flexibility and reduces capital expenditure for customers while ensuring a steady revenue stream for manufacturers.

Collaboration Between Technology Suppliers, Service Suppliers, and End-Users

Effective collaboration between technology suppliers, service suppliers, and end-users is essential for the success of lights out manufacturing. This collaboration ensures that all parties are aligned and working towards common goals. Regular communication, joint problem-solving, and shared objectives create a synergistic environment that drives innovation and efficiency.

Conclusion

Achieving lights out manufacturing through a collaborative ecosystem approach is a complex but attainable goal. It already happens around us. Think about earlier mentioned autonomous taxi’s and level-3 cars in the introduction video. By integrating ecosystem companies as mentioned, using relevant data and fostering collaboration, manufacturers can create a sustainable and efficient production environment. This approach not only enhances productivity but also promotes innovation and sustainability in the manufacturing sector.... And... People will still be playing an important role as part of the ecosystem.

Here are some notable real-world examples of lights out manufacturing:

FANUC: This Japanese robotics company has been operating a lights-out factory since 2001. Their factory produces robots at a rate of about 50 per 24-hour shift and can run unsupervised for up to 30 days12.

Philips: In the Netherlands, Philips uses lights-out manufacturing to produce electric razors. Their factory employs 128 robots and only nine human quality assurance workers to oversee the end of the manufacturing process12.

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