Written by: Adriano Valentinus S. & Venedicta Aurelia G.
Designed by: Zalika Afarin
Picture a factory that operates flawlessly, 24 hours a day, in complete darkness. No humans, no lights, just a symphony of machines and robots working in perfect coordination. This concept defines a manufacturing model that is fully dependent on automation, in which human involvement is replaced at every level of production, ensuring greater accuracy, stability, and efficiency. This is not a scene from an Iron Man movie, it’s the reality of the Lights-Out Factory, where automation and artificial intelligence give a new meaning to efficiency.
The Industrial Revolution 4.0 has brought us to a manufacturing process where factories run fully autonomously, called ‘Lights-Out’ Factory. This manufacturing approach enables production systems to function independently in facilities devoid of workers, where lighting and other human-centric infrastructure become unnecessary since automated machinery operates effectively in darkness. Implementing this demands the complete digitization and mechanization of all production stages, from raw material handling to final product packaging. Organizations adopting this approach rely on a combination of advanced technologies, including industrial robots, vision systems for automated inspection, 3D printing capabilities, IoT sensors for real-time monitoring, cloud-based data management, and machine learning for continuous process improvement. According to Gartner’s research, by 2025, 60% of manufacturers will have more than two completely lights-out processes in at least one of their facilities.
As a nation experiencing rapid technological advancement and automation development, China has also moved swiftly toward embracing lights-out manufacturing, which perfectly aligns with the national goal to become a global technology leader. Fully automated dark factories are becoming more common in different industries, from electronics and automotive to textile production. Xiaomi’s Changping Smart factory in Beijing is a great example of a company that successfully implemented the lights-out factory concept. Xiaomi takes a big step on their goals to maximize production utility with $330 Million Investment on Changping Smart Factory. The factory, standing in an 81,000m² facility, capable of producing up to 10 million flagship smartphones per year using robotics, AI, and autonomous logistics systems running continuously 24/7. This facility mainly manufactures Xiaomi flagship’s, MIX Fold 4, and MIX Flip smartphones. They operate 11 automated production lines controlled by AI systems that monitor and optimize the manufacturing process in real time.
However, this is not a new thing for a company named FANUC from Japan. FANUC has been implementing lights out factories since 2001 at their manufacturing facility in Yamanashi, Japan. This automated factory can operate unmanned for 30 consecutive days, running 24/7 to produce more than 6,000 robots per month, with a complex housing 22 factories that manufacture 22,000 to 23,000 computer numeric control machines monthly. To achieve fully autonomous operations, the facility employs various FANUC robots including the R-2000iB for assembly and material handling, the M-710ic/50 equipped with vision systems for autonomous adjustments, and the CRX-10iA cobot for 3D printing automation. These robots operate through Computer Numerical Control (CNC) systems, IoT sensor networks for real time monitoring, and AI powered quality control systems. The factory also employs Manufacturing Execution Systems (MES) and digital twin technology to coordinate all production for process optimization
Automation in manufacturing presents a double-edged sword with significant benefits and drawbacks. After initially high capital investment (CAPEX), Automation reduced long term operating cost (OPEX) through reduced labor costs, building maintenance, and human error. The Changping Smart Factory exemplifies this progress, operating almost autonomously with 96.8% of its packaging equipment built in-house, all factory software developed internally, and over 500 registered patents. However, these advancements come with substantial social concerns. The high initial investment creates financial barriers for many companies, while technical vulnerabilities pose serious risks—a single equipment failure can halt production entirely without on-site staff. Fully automated systems lack flexibility for quick adaptation to product design changes, and require highly specialized personnel like robotics engineers and data specialists who are scarce in many regions. Most critically, widespread job displacement affects traditional manufacturing workers who face unemployment without adequate reskilling programs. China’s industrial workforce declined from 30.3% to 29.1% between 2013 and 2023, while service sector employment grew from 38.4% to 48.1%, illustrating how automation shifts labor dynamics and potentially widens economic inequality between skilled and unskilled workers.
Indonesia’s readiness to adopt lights-out factory systems remains limited but steadily improving as the country advances its Industry 4.0 roadmap. Some multinational companies such as Schneider Electric’s Smart Factory in Batam have successfully developed high level automation and are recognized by the world economic forum. The main challenges of these digital transformations refer to limited availability of skilled professionals, high capital investment, and inconsistent infrastructure reliability. However, the government and private sector are working together to boost digital skills and strengthen industrial technology. Many training programs and university partnerships are now helping workers get ready for automation and smart manufacturing. However, Indonesia’s human resource readiness remains a concern, as the country already faces significant unemployment challenges. Moving forward, Indonesia must carefully balance automation adoption with employment protection, ensuring technological advancement and workforce security.
Indonesia’s challenges raise a bigger question: is lights-out manufacturing really the right path forward? Lights-out factories offer undeniable advantages, such as 24/7 productivity, zero human error, and significant cost savings, as proven by Xiaomi and Fanuc. It sounds like the golden standard of modern industry. Yet, in reality, even the most advanced facilities operate on hybrid models, still requiring human oversight for maintenance, exceptions, and critical decisions. Full automation demands equally significant trade-offs in flexibility, massive capital investment, and comes with profound social consequences like widespread job displacement. The question that remains is not whether lights-out manufacturing is impressive, but whether it’s the right path forward. With our unique industrial landscape and workforce dynamics in Indonesia, do you think lights-out factories can be successfully implemented here, or are we not quite ready for this level of automation?
References:
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