Lights-out logistics

Abstract

As technology advances, fully automated production processes are becoming more and more feasible as the norm, as many manufacturers' advantages outweigh the disadvantages. Driven by the need to produce faster, better, and cheaper, manufacturers of all sizes embrace various forms of automation in their quest to reduce costs, increase productivity and reduce response times. Automation is changing the face of manufacturing in ways previously unimaginable, from extensive production facilities almost entirely driven by robots to small workshops looking to improve a few key manufacturing processes. Fully self-driving plants are still not viable for most manufacturers, but more and more people are embracing automation on a smaller scale that makes sense for their business. This trend towards automation introduced us to a new concept: "Lights-Out." Automation in production, in particular, led to the development of "Lights-Out" manufacturing, which could operate 24 hours a day with minimal staff in the second and third shifts, and the concept was often associated with manufacturing. Considering that the term "Lights-Out" refers to a digitized, automated process that does not involve any human intervention, it can have an impact beyond manufacturing throughout supply chains. Many studies emphasize, albeit indirectly, the necessity of maximizing the intelligent use of technology, from automation to data analytics, especially in logistics processes. Practitioners use automated systems to make warehouses and distribution centers more flexible, provide optimum space utilization, and have similar efficiency concerns. Instead of trying to build a complete lighting plant, they are focusing on areas best suited to "Lights-Out" automation, such as material handling tasks. For example, no staff commuting with forklifts, no-load carriers inspecting products and picking up items on pallets, not even an electric light—just self-navigation with laser guidance systems, where high shelves, shuttles, elevators, robots, conveyors, and autonomous vehicles choose their path in the dark. They set up warehouses where they build, perceive obstacles and pass silently. At this point, the concept of 'Lights-Out Logistics' emerges. Furthermore, Lights-Out Logistics can help supply chains become more resilient in times of great uncertainty and disruption, such as financial crises and pandemics like COVID-19.