Motor technology accelerates shift towards fully autonomous manufacturing by 2030

By 2030, it is anticipated that 35 per cent of large manufacturing companies will operate fully autonomous facilities, a milestone highlighted by Industry 4.0 solutions specialist Intelligence Industrielle. This concept, widely known as “lights-out manufacturing,” envisages factories running with minimal human presence, leveraging advanced technologies to enhance productivity, safety, and sustainability. Mike Davies, managing director of Electro Mechanical Systems (EMS), outlines how sophisticated motor technology plays a pivotal role in realising this vision of the manufacturing future.

The World Economic Forum’s Global Lighthouse Network has been at the forefront of showcasing Industry 4.0 advancements. As of September 2025, the network has expanded to include 201 manufacturing facilities globally. These sites stand out for their pioneering adoption of automation, robotics, artificial intelligence (AI), digital twins, and data-driven production systems, each demonstrating measurable gains in productivity and sustainability. Although full lights-out manufacturing remains rare even within this elite group, success stories in sectors such as electronics from Vietnam and semiconductor manufacturing in Shanghai illustrate that near-complete autonomous operations are achievable.

Lights-out manufacturing offers significant operational advantages. These facilities operate continuously, boosting productivity by approximately 30 per cent while reducing product defects by around 40 per cent. Safety is enhanced by minimising human exposure to hazardous processes. Sustainability benefits also arise by optimising energy consumption through intelligent control of lighting, heating, and ventilation systems, thereby aligning with companies’ environmental objectives while reducing costs.

However, the shift to fully autonomous production facilities faces significant hurdles. Legacy machinery, often incompatible with modern digital and automation technologies, presents integration challenges that can disrupt workflows or force costly equipment upgrades. These investments can range from tens to hundreds of millions of pounds, depending on factory size and production intricacies.

Beyond infrastructural challenges, the technology underpinning these automated systems must meet exacting standards. Automated production relies on components engineered for precision, reliability, and efficiency, especially given the continuous and unsupervised nature of lights-out environments. Even minor faults in one system can cascade into wider production disruptions or quality control failures.

Motors are a fundamental component driving automation technology. Their ability to provide precise, repeatable motion is crucial for maintaining the integrity of automated processes. Advanced stepper motors, such as FAULHABER’s AM3248 series, exemplify this precision, offering micro-step control with compact designs capable of delivering high torque. These motors enable delicate tasks like pick-and-place assembly or inspection systems to function reliably with minimal human oversight.

Brushless DC motors complement these capabilities by providing long service life, high efficiency, and reduced maintenance requirements. Their use in autonomous guided vehicles (AGVs) and conveyor systems supports uninterrupted operation essential to lights-out production. Additionally, their low vibration properties help maintain accuracy in processes requiring fine detail, such as CNC machining and detailed inspections.

The advancements in motor technology underscore that while the development of smarter machines is important, the reliability and performance of each component within those systems ultimately determine the feasibility of fully autonomous manufacturing.

The Global Lighthouse Network’s continuing expansion, from 69 members in early 2021 to over 200 in 2025, reflects the rapid evolution and adoption of Industry 4.0 technologies. According to the World Economic Forum, Lighthouse factories have reported more than 50 per cent productivity improvements, over 80 per cent reductions in defects, and about a 30 per cent decrease in CO2 emissions, highlighting the dual economic and environmental benefits of these transformations. The network also fosters cross-sector collaboration, with many new members drawing lessons from established leaders, thereby accelerating collective progress towards a digitalised and sustainable manufacturing future.

While implementation costs and technical complexities remain barriers, the successes of the Lighthouse Network and the critical role of advanced motor components demonstrate a clear pathway to scalable lights-out manufacturing. As more manufacturers embrace Industry 4.0 technologies, the prospect of factories truly operating “in the dark,” with heightened efficiency and reduced environmental footprints, is becoming an attainable goal rather than a distant dream.

Electro Mechanical Systems (EMS), as the exclusive UK and Ireland supplier of FAULHABER motors, positions itself as a key enabler in this transition, emphasising that the motors at the heart of automation are instrumental not just as parts, but as foundational enablers of the lights-out manufacturing revolution.