When manufacturers talk about efficiency, the conversation usually sticks to materials, design tweaks, or streamlining processes. But some of the biggest gains aren’t happening during the day. They’re happening after hours, while the manufacturing floor is quiet and the lights are off.
At Broxton, we do not operate an expensive manned night shift, we use automation to manufacture whilst we’re asleep .
This isn’t new for us, we’ve been ‘lights out’ manufacturing for over 25 years. That said, our technology has advanced, so we produce more with less energy these days.
What Is Lights-Out Manufacturing?
Lights-out manufacturing means running automated CNC equipment with little to no human supervision. Once a job is set up, our automated production cells can run through the night or over the weekend, delivering finished parts by morning.
It's how we maintain speed, precision, and consistency without inflating costs. For OEMs, that translates to faster lead times, higher repeatability, and fewer headaches.
Why It Matters Now More Than Ever
Manufacturing today isn’t just about hitting deadlines. It’s about staying competitive and building free capacity tightening tolerances, and keeping costs under control.
Lights-out machining helps us do exactly that:
- Reduced production lead times and dependence on manned shifts
- Lower labour overhead
- Ability to flex capacity ramp up production - More output without more headcount
And for urgent or repeat jobs? It means we can produce parts during downtime without cutting corners.
Why It Should Be the Industry Norm
Too often, lights-out capability is treated like a futuristic bonus. At Broxton, we see it differently. If you’re serious about delivering consistent quality and tight lead times, automation isn’t optional it’s essential for the business to run.
But it's not just about owning the right machines. You need the right systems:
- Smart fixturing
- Tool life monitoring
- In-process checks
- Skilled engineers who set up jobs to run cleanly from the first part to the last
How We Do It at Broxton
Here’s what lights-out machining looks like in our facility:
- 40 pallet, 5-axis CNC mills
- Mill-Turn fixed and sliding head lathes with subspindles, bar feed and part removal for long, unattended runs
- Scheduling that blends human and unmanned cycles for maximum output
- Setup routines that ensure every job runs right the first time
We haven’t replaced craftsmanship, we've just scaled it. Automation lets us apply the same attention to detail, just with more efficiency and less downtime.
Final Thought
Lights-out machining isn’t about replacing people, it’s about using their time wisely. Our team focuses on what matters: setup, problem-solving, and quality control. Machines handle the repetition and the heavy lifting.
This means shorter lead times, fewer errors and more value for our customers and that’s what matters most to us.
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