Will the US ever have fully automated ‘dark factories’?

Core Insights - The article discusses the increasing use of AI and automation in the manufacturing industry, particularly contrasting the U.S. with countries like China and Japan that have long utilized fully automated factories [1][4]. Group 1: Automation in Manufacturing - "Dark" or "lights-out" factories operate 24/7 with minimal human intervention, utilizing machines and robots [2]. - A notable example is a Fanuc factory in Japan, which operates for a month with minimal human input, producing robots at a rate of 50 per 24-hour shift [3]. - Philips has a similar setup in the Netherlands, where over 120 robots operate with fewer than 10 workers for quality assurance [3]. Group 2: U.S. Adoption of Automation - U.S. manufacturers have been experimenting with automation, especially post-pandemic, but there are no fully automated plants in the region yet [4]. - Tesla's gigafactories represent the closest approach to "dark" factories in the U.S., with 90% automation reported at its Nevada plant [5]. - Most U.S. manufacturers are pursuing gradual automation rather than building entirely new dark factories [6]. Group 3: Challenges and Costs - The U.S. approach often involves retrofitting existing facilities designed for human operations, which incurs upfront costs that many companies may not be prepared to handle [7]. - Implementing automation is expensive, leading most manufacturers to phase it in gradually to ensure financial viability and a clear return on investment [8].