4 Bright Ideas for Effective Lights-Out Machining

With the skills shortage still an obstacle in machine shops everywhere, unattended or lightly attended machining is becoming a necessity for many manufacturers. The ability to produce parts without an operator at the machine and/or lights-out (overnight) machining offers benefits such as a decrease in staffing costs, an increase in production capacity and enhanced flexibility by enabling longer running jobs that do not require supervision.

However, moving into lights-out machining can be a challenging transition and is not as simple as automating a few processes and hoping for the best. There are a multitude of factors to consider and changes that need to happen to ensure a shop is ready to run unattended. The improvements to efficiency and profitability make it an investigation worth doing.

Dim the lights before putting them out completely. As attractive as the idea is to pump out a day's worth of production overnight, there is no need to rush into it. If there are multiple machines being considered for lights out, do not plan to put all of them into unattended production at once. Use one or two machines as a test case and see how it goes.

Similarly, do not try to get an entire production line ready in one go. Take incremental steps to test each section of the production process to discover potential issues when they are running unattended. Then, slowly build up to a fully operational production line.

Be smart about the jobs you choose to run unattended. Initially, it is wise to select simple projects that are less likely to be problematic and need supervisor intervention. Speed is less important than accuracy and reliability in lights-out production. The staff overhead is not the same, so ensuring greater quality by slowing down the process is worth it. Similarly, going slightly slower to avoid potential quality problems with tools makes sense when the machines are running unsupervised. 

Ideally, do not run a job overnight that has not been tested with operators present during the day. Not checking that everything works prior to running it lights out is asking for trouble.

Ensure that all systems are in place. There is more to running lights out than simply having the automation in place that enables the process. Other elements of the process need to be up to the task as well. Consider:

• How reliable are the services to the machines (such as power and air)?
• What happens if there is a power outage?
• Are the fire suppression systems adequate?
• Is the management of coolant and coolant applications sufficient?
• Are the machines monitored remotely, and how are operators notified of any issues?

Ensuring a high level of preventive maintenance across every element of the process becomes even more vital when considering lights-out production. A little quirk of the machine that an operator handles on the go can become a real problem when unsupervised. So, make certain the staff reports even the smallest of issues that might cause problems.

Monitoring is invaluable. Take Anca's Redax, for example. This real-time monitoring software not only delivers up-to-date information about every machine on the floor but can send emails and SMS notifications to specified recipients as needed.

It is also vital to be able to guarantee quality control. There is no value in producing parts all night that are defective. A premium in-machine tool measurement system, like Anca's LaserUltra, can automatically compare the tool with its required geometry and make the necessary compensation to ensure consistency.

Maybe keep one light on. It is worth pointing out that unattended production does not have to be taken literally. There are benefits to having at least one operator supervising the night shift, even if he/she ends up not having to do anything. Proper automation will ensure receiving a significant increase in productivity for the nominal cost of one wage.