What?
Lights-out production is an approach to manufacturing where no human intervention is required to run a machine for a specific duration of time. Normally, it can be difficult to understand how beneficial adding a lights-out shift is since no one is around to monitor the machines as they run. To get the data you need, it usually requires paying someone to stay overnight to monitor output and track when the machine goes down. This takes time and can often be inaccurate.
However, you can use Amper's utilization data to help—without the hassle of overtime and extra paperwork.
Time Commitment: Medium
Features Required: Utilization Monitoring
Notes: Will require situations like part loading robot, long cycle times, bar feeder, etc. Cannot be easily replicated on all shops and equipment.
Case Studies:
Read how the team at Destaco - Mt. Juliet used Amper data to justify more machines that can run lights out production and see their results!
How?
- First, add a 24 hour shift to Amper (shown below in orange) to test how the machine can perform during lights-out production.
2. Then, run your machines on lights-out production to track utilization.
3. To determine if it is working, look at the utilization dashboard week over week.
4. Continue to test lights out production for for 4-8 weeks. Use Amper to see how many more hours of production your machines can run, and determine if it's worth it to make lights out a standard operating procedure at your plant. Some Amper customers set a goal for hours of lights out production in a month, and track their performance weekly. This low cost production can justify costly maintenance or automation to keep the machines running during this time.
5. If some machines run lights out better than others, the added production time may justify getting more of these machines.