Do you want to save money on your plastic molding projects? Lights Out Manufacturing
- Plastic Molding MFG
- Jul 7
- 2 min read
Updated: Aug 21
Find out how Plastic Molding Manufacturing Uses Lights-Out Manufacturing to save you time and money!
Plastic Molding Manufacturing blends industry expertise with advanced automation to deliver high-quality, cost-effective solutions. A key part of our strategy is “lights-out manufacturing,” which helps increase efficiency, reduce costs, and meet growing production demands.
What Is Lights-Out Manufacturing?
Lights-out manufacturing is a highly automated process where machines run with minimal or no human supervision. While none of our four U.S. facilities are fully lights-out, they are equipped with the technology to operate that way when needed. This approach is used to:
Extend production beyond regular shifts.
Lower labor and operational costs.
Speed up production for large orders.
CNC and Automation Technology
We use advanced CNC (Computer Numerical Control) machinery, which can run unattended overnight or on weekends. Although technicians remain nearby to monitor issues, automation reduces the need for constant human presence.
CNC technology has transformed our operations by providing:
Precision and Consistency: Machines deliver high-accuracy, repeatable results, critical for industries like aerospace, medical, and automotive.
Complex Design Capability: CNCs can manage intricate shapes and designs that are difficult or impossible to make manually.
Improved Efficiency: Automated trimming and shaping significantly reduces production times.
Scalability: Whether for small prototypes or mass production, CNC systems maintain consistent quality.
Combining Technology with Human Expertise
We do not rely solely on machines. Instead, we use a hybrid model that merges automation with skilled labor. By integrating technologies such as remote monitoring, planned maintenance, real-time data analytics, and smart scheduling ensure that systems stay efficient and responsive. For example, 65-75% of the parts in our Indiana plant have the ability to run lights out. This model supports two fully staffed shifts and one completely automated, unmanned shift—enabling us to meet customer demands effectively.
Maintenance and Technical Challenges
Implementing lights-out manufacturing involves significant initial investment and overcoming various technical challenges. Although automation reduces human error, machines still require ongoing attention. Key considerations include Equipment, Setup, Process, and Tooling. If the tooling quality is poor, running production without human oversight is not advisable. At Plastic Molding Manufacturing, we leverage our expertise in tooling design and construction to support lights-out operations. In addition, we utilize preventive maintenance, scheduled repairs, and monitoring systems to detect and address issues before they impact production.
Automation for the Right Tasks
We apply automation where it makes the most sense—simple, repetitive tasks. Complex jobs, quality control, and system oversight are still handled by skilled professionals. This balance ensures high productivity without sacrificing precision.
Nationwide Support and Industry Reach
With locations in Massachusetts, Connecticut, Indiana, and Pennsylvania, we support customers across the U.S. Their services span a variety of sectors including:
Medical
Transportation
Consumer products
Industrial manufacturing
Defense
Connectors
We offer end-to-end solutions to help partners improve performance and product quality.
Looking Ahead
At Plastic Molding Manufacturing we continue to invest in smart technologies, software, and network systems to stay ahead in a competitive market. By combining automation with expert human input, we are shaping the future of manufacturing and helping customers remain competitive in rapidly changing industries.