June 15, 2022
Yash BhatnagarWhen I first heard about Dark Factory, I thought we were heading towards Industry 5.0, but it’s still unclear. Maybe there is more before the complete shift. Automation is already hugely impacting Manufacturing but a model without man and machines managing end to end may bring the era of complete lights-out i.e. machines operating as they are programmed to complete their tasks, even with the lights off.
Industry 4.0 is no longer just a catchy buzzword. Manufacturing executives get visibly excited when using the term Industry 4.0. Although Industry 4.0 has attained reasonable maturity, the term still evokes many questions – what is Industry 4.0, and how does it impact manufacturing?
Industry 4.0 is coming together with manufacturing and information technology. It is characterised by the extensive deployment of cyber-physical systems and the Internet of Things (IoT), wherein people, machines, products, and software systems communicate in real-time to enable autonomous production.
Although the technology has driven the entire world, Singapore has taken the lead in developing and using advanced manufacturing technologies. It has over 2700 precision engineering firms producing critical products and providing expertise to incorporate smart manufacturing in various industries, manufacturing essential goods for medical technology, semiconductors, and aerospace.
Will the Technological Shift Lead to Dark Factories?
With this acceleration in disruptive and digital technologies, there is a possibility that fully automated “light-out environments” or dark factories will be a reality. The autonomous production within a lights-out factory is likely to grow throughout the industrial spectrum as manufacturing organisations explore the “factory of the future.”
The advancement and maturity of various automated machines & robots and complete and established manufacturing operations management (MOM) software make lights-out factories possible. Since the software can manage automated manufacturing processes without any assistance, it also offers visibility into self-produced goods. Moreover, human stakeholders can monitor lights-out operations from a distance and receive warnings to do additional tasks or interventions.
Manufacturers may also benefit from a “lights-sparse” environment where the dark factory model is limited to specific areas. Therefore, many businesses would be able to reap the benefits of autonomous manufacturing without committing to a full-fledged lights-out operation.
What are the Advantages of Dark Production?
Dark Factory is now a reality, and it is on its way to becoming the new norm for mass production. The expansion of lights-out production can be attributed to several factors, including:
• Lower Production Costs – The primary benefit of dark manufacturing is low costs. Employee salaries are eliminated due to the lack of a workforce, as articulated robots can work in dark and non-climate-controlled situations, thereby conserving the utilities.
• Refines Environmental Footprint – Lights-out manufacturing is a sustainable manufacturing strategy that reduces the impact on the environment. Industrial robots that are newer are more energy efficient. Also, the excellent precision of robots reduces material waste and scrap, and since robots are carbon-free, they help reduce pollution levels.
• Enhanced Productivity and Product Quality: Since a single robot can complete tasks that would typically need multiple employees, robots help boost plant productivity substantially. Besides, accuracy and precision lead to better product quality. As robots are designed to obey application-specific instructions, uniformity in workpieces results in minimal inconsistencies.
• Eliminates Labour Shortages: Manufacturers have faced labour shortages in recent years, particularly for skilled labour roles. The pool of employees interested in manual labour has shrunk, making it challenging to fill vacancies. This problem is solved by using automated equipment to fill robotic positioners instead of employees in dark factories.
Paving the Way to a Brighter Future
The future of manufacturing is definitely in conjunction with the dark factories. Many manufacturers are successfully pushing technology ventures past the pilot stage. Moreover, many smart factories worldwide will serve as solid examples of properly integrating industrial IoT solutions that have a real-world impact.
Singapore has emerged as a regional leader and a place where companies and manufacturers can co-create and develop smart technologies together. It has also emerged as a leading nation in terms of robotics investment in Industry 4.0, where the goal is to explore new technologies and reduce costs across the manufacturing process. Nevertheless, as this digitisation becomes the market standard, the desire to adapt will be heightened due to the competitive pressure and help the savviest companies bring the best out of it.
About the Author:
With more than 22 years of IT experience in various leadership roles across the globe in multi-cultured environments in managing Global IT Sales, Delivery Management, Client Relationship Management and Sales, Establishing a business in new geographies, Large deals Program Management and Solution Designing, HR (Talent Acquisition and workforce operations), Transition and Bid Management. Yash also managed the IT deliveries, created a local partner ecosystem for effective resource mobilization, leveraging Global deliveries at various offshore locations, Managing the account and key client relationships, establishing and running nearshore development centres in Japan.
