Enterprise leaders seeking reduced overheads are turning to autonomous operations to drive efficiency across distributed assets.
The “lights-out” factory concept is decades old, but edge computing, reliable connectivity, and improved data governance now allow plant managers to move past isolated pilots.
Sessions during day one of this year’s co-located IoT Tech Expo Global and Edge Computing Expo demonstrated that although the technology for autonomy is ready, the organisational structures and security frameworks to support it are not.
Transitioning to autonomous operations
Moving from connected machines to fully autonomous environments requires operational and cultural changes. A panel on “Lights-Out Manufacturing” explored the shifts necessary to support factories running with minimal human intervention. Mark Sage from AREA and Paul O’Sullivan from Salesforce discussed how manufacturers must integrate real-time data and robotics to enable this automation.
OT directors see value in reduced downtime and increased throughput without proportional labor cost increases. However, achieving this state requires a resilient architecture.
A cross-industry panel featuring Ryan Courtier from Citi and Mohsen Ghasempour from Kingfisher examined how edge intelligence reshapes logistics and energy alongside manufacturing. Panelists argued that reliance on centralised cloud processing introduces latency that autonomous systems cannot tolerate.
System continuity depends on the ability to function while disconnected. Perla Maiolino of the Oxford Robotics Institute presented on building intelligent physical systems that operate without cloud dependency. Using multimodal sensing and local inference, these systems maintain continuity during network outages. This capability is mandatory for plants where uptime dictates revenue.
Scaling edge infrastructure
Deploying a single autonomous unit is very different from managing a fleet. Supply chain executives face complexity when scaling these deployments.
The panel “Scaling the Edge” addressed interoperability and cost management in large-scale rollouts. Edith-Clare Hall of ARIA and Matthew Howard from IEEE Robotics & Automation Society shared lessons on the operational complexity arising when disparate systems attempt to communicate.
Siloed data streams result in fragmented visibility. Oluwatobi Musa from Brent Council argued for platform-based approaches to manage distributed edge AI infrastructure. Standardising the management layer reduces the technical debt of maintaining custom integrations for every new device. This approach improves reliability and creates a consistent environment for application development.
Standardisation also helps process the volume of data generated by modern sensors. Musa’s session on “Edge-Native IoT Architectures” noted that processing data at the source reduces latency and supports real-time decision-making. For a utility provider or a logistics firm, this enables reaction to grid fluctuations or routing changes in milliseconds.
Digital twins and data fidelity
Autonomous system efficacy depends on digital representation accuracy. Gift Ojeabulu from DevNetwork explained how unified CNC, SCADA, and facility data build digital twins that improve visibility. These models act as operational tools for decision-making rather than just planning assets.
Connectivity supports this fidelity. Ojeabulu detailed how global IoT connectivity standards, such as SGP.32, enable next-generation digital twins to maintain real-time data accuracy.
When data feeds are reliable, predictive maintenance becomes a viable strategy. Maiolino showed how these data feeds enable predictive digital twins to optimise operations and reduce downtime. Plant managers can then repair components during scheduled breaks rather than halting lines during peak production.
Securing the distributed attack surface
Connecting more devices expands the attack surface. Security remains a primary concern for boards evaluating IoT investments.
Rogin Robert from Forvis Mazars presented on “Securing IoT Through Internal Audit,” outlining how audit frameworks apply to IoT environments to improve governance. Robert argued that complex IoT risks must translate into board-level clarity.
Securing the perimeter is insufficient; the devices themselves require monitoring. A session on protecting distributed devices covered the threat landscape, including supply-chain risks and device-level vulnerabilities. As OT environments merge with IT networks, applying rigorous internal audit standards ensures that a breach in a sensor does not become a breach in the corporate network.
Achieving lights-out manufacturing is an iterative process. It starts with securing the edge, ensuring data fidelity through digital twins, and adopting platform architectures that allow for scale. The technology discussed during day one of this year’s IoT Tech Expo Global and Edge Computing Expo shows that the tools for autonomy exist, but implementation relies on disciplined integration and governance.
See also: The edge possibilities at IoT Tech Expo 2026
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