6 points to consider before going lights-out

Lights-out machining, also known as unattended or ghost-shift machining, is the gold standard for CNC productivity. The goal is simple: keep machines running efficiently, even when the lights are off and the floor is empty. But the path to achieving this goal is more complex than most realize.

In the following 6 points, we will break down the critical requirements for lights-out success, the weak points that often go unnoticed, and why coolant automation may be the key to scaling uptime without increasing headcount.

Lights-Out Readiness Checklist

Before you set your machines on autopilot, evaluate these core areas.

1. Tooling

Do you have breakage detection, redundant tooling, or load monitoring?
Without it, a single broken insert could render an entire shift worthless. Modern tool monitoring systems, which utilize load sensors or acoustic emissions, are essential for preventing catastrophic damage.

2. Fixturing

Reliable lights-out machining starts at the point of contact. Your fixturing must deliver repeatable, error-free positioning across every cycle. CNC setups should leverage hydraulic or pneumatic clamping systems equipped with sensor validation or pressure feedback to confirm secure clamping before a cycle begins. This prevents crashes, misloads, and costly spindle downtime—issues that human oversight would normally catch.

3. Part Loading

Do you have automation for material handling?
If not, human labor becomes the limiting factor. Automated solutions, such as bar feeders and pallet systems, enable uninterrupted part cycling during overnight or weekend production runs.

4. Coolant Delivery

Can your machines maintain proper coolant levels and concentration without intervention?
Manual top-ups won’t cut it. The whole shift fails if your coolant runs dry or the concentration drifts. Systems like FlexxCool automate sump filling and control per-machine concentration targets, ensuring reliable operation even when no one is around.

5. Chip Management

Do you have conveyors and filtration in place to handle chips overnight?
Neglected chip evacuation leads to jams, part damage, or shutdowns. Effective chip handling systems are mandatory for lights-out success.

6. Alarm Handling

Can your systems identify issues and alert staff or shut down safely?
Remote alerting and safe-stop programming prevent downtime from spiralling into damage or scrap. These systems buy you time to respond, even from home.

Where FlexxCool Can Help

Coolant is one of the most common and preventable causes of lights-out failure. In most shops, operators still manually mix and fill coolant. That’s a liability if you’re not physically present when the tank runs low or the mixture shifts out of spec.

FlexxCool addresses this with purpose-built automation:

• Automated delivery to each machine’s sump
• Precision mixing to machine-specific concentration targets
• Top-up queueing when multiple machines need coolant simultaneously
• Remote alerts for flow issues, low concentrate, or other system conditions
• Data logging for usage, trends, and optimization over time

By eliminating manual intervention, FlexxCool turns coolant from a weakness into a strength.

Final Takeaway

Lights-out machining is more than just buying a robot —it’s a complete strategy. Every dependency, sensor, and input must be engineered to operate without failure. The weakest link in that chain will always fail first.

Coolant systems are often overlooked. FlexxCool was built to close that gap. With automated top-ups, smart concentration control, and remote monitoring, FlexxCool enables manufacturers to unlock true lights-out performance.

If you’re serious about 24/7 machining, it’s time to automate the parts of your process that can’t afford human error.

Let’s Talk

Is your shop exploring lights-out machining?
Let’s discuss how FlexxCool can integrate into your strategy.
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