China takes a step further in automation and AI with ‘dark factories’

A “lights-out factory,” or dark factory, is a fully automated manufacturing facility that runs with little to no human intervention, using robotics and artificial intelligence to operate continuously. These “smart” factories can run unmanned, day and night, by automating tasks like production, assembly, and even quality control. The concept allows for uninterrupted operations and is a significant trend in modern manufacturing, exemplified by companies like FANUC. 

This video shows a lights-out factory in Japan where robots are building other robots: 

What China is Doing: Dark Factories

China has made several concrete moves toward deploying dark factories on large scales:

Xiaomi’s Dark Factory (Changping, Beijing) An ~81,000 m² facility that operates 24/7 without people on the floor (lights off, etc.).  It costs about 2.4 billion yuan (~US$330 million) and has capacity to produce ~10 million smartphones/year.  All key processes are automated (assembly, inspection, packaging etc.) via Xiaomi’s own systems.  Other Factories & Sectors Megvii built a “black-light” model workshop in Zhejiang for motor/drive manufacturing.  Baogang Group in Inner Mongolia: robots separating slag from molten steel, performing dangerous tasks without human workers in those parts.  Gree Electric Appliances upgrading a plant (with Huawei, Unicom) into a “5.5G native lights-out” factory. 

Key characteristics:

• High Automation:Lights-out factories rely heavily on robotic systems, artificial intelligence, and advanced software to manage production processes.
• Unmanned Operation:The goal is to operate for extended periods, or even 24/7, without human operators on the factory floor.
• Remote Monitoring:While human input is minimized, these factories are still monitored remotely, and human staff are typically involved in maintenance, troubleshooting, and higher-level oversight.
• Increased Efficiency:By removing human constraints, these factories can achieve higher production rates and consistency.
• “Dark” Concept:The term “dark” comes from the ability to run the facility with the lights off, as the machines do not require human presence or illumination to function.

How they work:

1. 1. Robotic Processes:Robots handle a wide range of tasks, from assembling parts to packaging finished products.
2. 2. AI and Sensors:Artificial intelligence and networked sensors enable autonomous process control, ensuring smooth operation and maintaining quality standards.
3. 3. Automated Logistics:Automated guided vehicles (AGVs) and other automated systems transport materials and finished goods within the factory.
4. 4. Self-Correction:Smart systems can detect issues, make adjustments, and even perform quality checks without human intervention.

This video explains what lights-out manufacturing is and how it works: 

Benefits:

• Continuous Productivity:Uninterrupted operations lead to higher output and efficiency.
• Cost Reduction: Reduced labor costs and minimized downtime contribute to operational savings.
• Improved Quality and Consistency: Automation ensures precision and reduces human error.
• Enhanced Safety: Removing humans from dangerous or repetitive tasks improves worker safety.

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