Lights-out manufacturing is getting lots of attention. China is all-in. So, how far is America from fully autonomous manufacturing?
Lights-out manufacturing is getting a lot of buzz.
In fact, factories in China are literally going lights-out. This means human involvement in the manufacturing process is either minimal or nonexistent, making lights unnecessary. Human workers can turn the lights off behind them, and production continues, unhindered.
And Plant Engineering‘s research shows there’s a hearty appetite for robotics, automation and artificial intelligence from U.S. manufacturers.
The manufacturers we surveyed in our 2026 State of Manufacturing Operations & Maintenance Study said they’re looking to make investments in all of these technologies. Almost 80% of the manufacturing leaders we surveyed said they intend to invest in these automation-related technologies in the coming year.
About 39% said they plan to invest in robotics and automation in 2026 as a way to improve operational efficiency. Another 39% said they’ll invest in AI. And interest in AI as an investment has spiked from 2025. Only 28% said they had plans to invest in AI in 2025.
China’s robotics gamble
Making those investments in robotics and automation is a first step. But the U.S. is already trailing behind other countries when it comes to entrusting their manufacturing to machines.
China installed 276,000 industrial robots at plants in 2023, more than all other countries combined. During the same period, American manufacturers installed 38,000 industrial robots. When you consider a total of 540,000 new industrial robots were installed in 2023, China’s share of that is astronomical.
Phasing in automation
For American manufacturers, a phased approach is likely the best approach.
Plant managers and other manufacturing leaders face a challenge when it comes to justifying capital expenditures. Some positive news is emerging, according to our research. There was an 11% increase in facilities allocating 21% to 30% of their operating budget for technology from 2025.
And phasing in automation technologies has a number of advantages, especially given the challenges plants face.
Those challenges include:
- High upfront capital expenses
- Workforce training
- Unpredictable component shortages
Automation has to be profitable before it will be widely adopted. And high upfront capital costs are a barrier for many manufacturers, particularly small- and medium-sized plants.
But even for larger plants that have the budget, training and re-skilling workers poses another set of challenges.
And another challenges comes from components. To be fully automated, plants rely upon predictable material flows. If there’s a shortage somewhere along the supply chain, this puts a big wrench in the whole process.
What does a phased automation approach look like?
So, what does a phased approach to full automation look like?
Phase 1 – Attended Automation: A human operator is present for loading, unloading and quality control, but core processes are automated.
Phase 2 – Extended Unattended Automation: Automated processes run through breaks and partial shifts without a human operator present.
Phase 3 – Unattended Shifts: Processes are automated for entire shifts without personnel on the plant floor.
Phase 4 – Multi-Shift Lights-Out: Processes are fully automated and run 24/7 without the need for human operators.
And this doesn’t even cover human attitudes towards fully automated, lights-out processes. Let us know. Does lights-out automation in manufacturing scare you? Is it an exciting development? Or is it a threat to human jobs?
