Why Even the Most Automated Factories Need a Human Touch?

[Cengiz Özemli]

## Why Even the Most Automated Factories Still Need the Human Touch

Fully automated production is not a new concept; from mythology to the industrial revolution, humanity has questioned and shaped the role of machines in the workforce. Today, as artificial intelligence (AI) and automation rapidly advance, the balance between the human factor and machines has become even more critical.

"Dark factories" or "lights-out" manufacturing facilities, the modern equivalent of unmanned production systems, can produce without human intervention using industrial robotics, IIoT, AI, and machine learning technologies. However, full automation also has its limitations. Especially in the US, product variety, short production cycles, and regulations make human oversight indispensable.

### Limitations of Automated and Fully Automated Production

• Automation provides high efficiency in repetitive, stable, and predictable tasks.
• However, dynamic and variable processes are difficult to manage without human intelligence and intuition.
• Complex situations such as food safety tests or urgent recalls require human intervention.

### The Balance Between Human and Machine is Important

Despite the allure of full automation, human decision-making ability is needed for flexibility and rapid adaptation in the face of changing conditions. Therefore, hybrid production models, combining machine precision with human judgment, yield the best results in production.

### Recommendations for Effective Automation

• Identify processes where autonomy adds value but adaptability is maintained.
• Retain human responsibility for critical decisions.
• Train the workforce with digital skills and enable them to collaborate with machines.
• Create flexible designs and processes for human intervention.

### Dark Factories and the Human Factor

While automated systems perform their tasks effectively, the valuable contribution of humans emerges in adapting to changing conditions. Focusing automation on specific areas of production and training employees to use these technologies is critical for balancing efficiency and reliability.