1. Smart Trade-offs
Paul, a very experienced machinist, talked through his experience on how to make the
most of Lights Out Machining. One of his key takeaways was how to trade off between risk and time. Historically with manned machining the cycle time of components is critical, especially for larger runs. Removing 30 seconds from a programme over hundreds of components is a huge time and cost saving. Lights Out Machining may require a slightly different perspective.

Where more complex programs and tool paths to save time may be worthwhile while operators are monitoring, the potential impact on unmanned operations is huge. In some cases, an event caused by using more novel or unproven programs could cause the loss of several hours (or even days) of machining time. The key message from Paul is ‘Repeatability’.

Think about the type of jobs you want to run overnight or through the weekend. Is it a proven method and set-up that has rarely caused failures? (The value of data in assessing this is not to be underestimated!) Or, is it a new novel part?

Even if the simulations on the CAD software look fine, the reality can always be different.

2. Smart Tooling
Machine tool operators will regularly assess dimensional accuracy through the lifecycle of
a job. As tools wear, certain features may move close to or out of tolerance, signaling a need for tool changes. Modern machines are now able to deploy probes to assess dimensions at a sample frequency, from this making judgements as to whether tool changes are required.

Understanding machine capability in this space could be the difference between dozens of conforming and non-conforming parts.

3. The Value of Time and Measuring Productivity
Lights Out Machining requires a rethink on the value of machinists’ time and productivity. Taking Paul’s example, he could spend eight hours producing only a handful of parts across three different machines which on face value might seem like poor productivity, but all this time is spent preparing multiple machines to run Lights Out. Over the course of the 12 hours following Paul’s shift, the machines are hugely productive.

Spending time assessing part quality on the CMM as the ultimate measure of conformity takes up time and resource in the QA department as well, but goes towards assuring the next 12 hours (on three machines) produce parts right first time.

This rethink of how to measure productivity will become more important in the years to come as more Lights Out Machining takes place.

4. What’s in it For Me?
Because a greater value can be achieved from a single hour of work from an experienced machinist using Lights Out capabilities, the need for more flexible working situations is arising in machine shops around the world.

Machinists traditionally would be left out of the flexible working discussion because their productivity was
tied solely to operating machines.

In situations where all machines might be set up running without operators, those operators could be deployed doing new programmes or continuous improvement activities. Similarly, one hour of work at the weekend might equate to huge value to the business, if it means the machine is reset and can keep producing for another 24 hours without an operator. As such, incentive schemes to be in work for as little as 30 minutes, that are win-win for operators and the business, are becoming more common.

Retention – with more attention being placed on retaining good staff, Lights Out Machining offers opportunities to engage staff in new technologies and opportunities to learn and test themselves, while potentially enabling some more flexible or win-win working patterns.