In many factories, achieving continuous 24-hour production isn’t just a question of material loading. More often, the real bottlenecks appear at the output stage and in the manual processes that follow: inspection, part handling, and the space consumed by unloading and sorting operations.
Even in today’s manufacturing environments, where partial automation is common, production frequently comes to a halt. Why?
Because:
- Material storage capacity is limited, requiring frequent operator intervention
- Tool changes depend on manual wear checks
- Dimensional inspection and finished-part handling require constant human presence, occupy valuable floor space, and introduce downtime between processes
So why doesn’t a production line simply “run by itself”?
Muratec Case Study #28: Tackling Input, Process and Output
In Muratec case study #28, a comprehensive solution is presented that addresses the entire production chain — input, machining process and output — with particular focus on the final phase and its impact on overall autonomy.
Key elements of the solution include:
- Raw material change
Switching from bar stock to pre-cut material, combined with a dedicated feeder, enables sufficient material capacity for up to 24 hours of continuous operation. - Automatic tool change
Integrated tool life management continuously monitors wear and automatically switches to a reserve tool without stopping the machine, eliminating manual intervention. - Automated inspection and sorting
An integrated measurement system replaces 4–5 minutes of manual inspection per part, while a tray-based feeder automatically sorts finished components ready for packing. This reduces floor-space requirements and eliminates unnecessary downstream handling.
The Result for the Plant
The outcome is a production line that operates virtually unattended. Only periodic maintenance and consumable replacement are required, while the system maintains stable output, improves operator safety, and significantly reduces reliance on labour for repetitive, low-value tasks.
For manufacturers targeting true lights-out or near-lights-out production, the real gains lie not only in machining automation, but in solving what happens before and after the cut.
