Humanless manufacturing is rapidly expanding worldwide. Companies like FANUC, Philips, and GE now operate factories with minimal human supervision. While automation has already eliminated 1.7 million U.S. manufacturing jobs since 2000, experts predict a mixed future. AI factories could displace 300 million jobs globally, but may also create 97 million new roles requiring different skills. The transformation demands massive investment but yields substantial returns for companies that successfully implement these systems.
A quiet uprising is happening on factory floors around the world. Lights remain off as robots work tirelessly in the dark. These “lights-out” factories operate 24/7 without human workers present. No need for lights, heating, or air conditioning when machines do all the work.
This concept isn’t new. IBM first tried it in the 1980s to make keyboards. Today, several companies have achieved nearly humanless manufacturing. FANUC, a Japanese robotics company, has run lights-out since 2001. Their robots actually build other robots with minimal human oversight. Philips produces electric razors in the Netherlands with just nine human workers. GE and Xpeng Motors have similar setups.
The advantages are clear. These factories boost productivity and improve quality control. They don’t need breaks, don’t get sick, and don’t make human errors. Companies save on labor costs and can operate continuously, making them more competitive globally.
But there’s a concerning side to this transformation. Experts predict automation could displace 300 million full-time jobs worldwide. About 14% of workers already report being replaced by automation, and 44% of companies using AI expect layoffs due to automation by 2024.
The change isn’t cheap or simple. Setting up lights-out factories requires massive investment. These systems can’t easily adapt to sudden product changes. They also need skilled technicians for maintenance and face cybersecurity risks. Optimized factory layouts for autonomous robots can significantly enhance production capacity while reducing energy consumption. Studies show businesses implementing AI solutions achieve an average return on investment of 267% despite high initial costs.
AI’s impact on manufacturing jobs will grow. By 2030, AI may affect 80% of the U.S. workforce. Since 2000, automation has already eliminated 1.7 million manufacturing jobs in the United States alone. While 85 million jobs could disappear, forecasts suggest 97 million new positions might emerge in AI training, machine maintenance, and system design.
The shift demands new skills. Workers will need training in robotics, AI, and machine learning. Companies and governments are creating programs to help workers adapt to these new roles. The factory of the future might have fewer humans, but it’ll need people with different skills working alongside the machines.
