7 Common Automation Mistakes (and How to Avoid Them)
Implementing automation is rarely a walk in the park. Doing so successfully is an even bigger challenge. Yet more manufacturers than ever — about 53%, according to ABI research — are in the early stages of adopting automation, with another 28% having already deployed robots in their facilities.
There are several key pitfalls that many companies fall prey to when implementing automation. Read on to learn what these are, how they can impact businesses, and ways they can be avoided to ensure a successful implementation.
1. Failure to plan or clearly define goals
Extensive planning should be the first phase in any automation project. This is when expectations are set, goals are defined, and stakeholders determine what processes can or should be automated and how to do so.
The key challenge in the planning phase is bringing together all stakeholders and analyzing the problem holistically. Failure to do so can result in problems and expenses down the line, such as:
Project delays, missed deadlines, and uncertain outcomes
Missed opportunities for more comprehensive automation
Frustration and lowered morale of the implementation team
Expensive redesign and redeployment of robots
“Often, people try to fix problems at the end of the production line with automation that are caused somewhere else on the line. A good example is that customers tend to produce a part and then drop it into a bin. We then need to install an expensive part separation system to singulate these components again from the bin. Instead, we try to understand how we can work on the parts right out of the machine.”
How to fix it! The number one way to avoid this pitfall is to plan early and thoroughly. By bringing together a cross-functional, agile team, an effective plan can be put into place and successfully executed.
2. Choosing the wrong equipment
The choice between different types of industrial robots — deltas, gantries, robot arms, etc. — will vastly impact the capabilities of your application. It’s vital to understand what exactly you need your robot to achieve before selecting one. A high-speed delta may be perfect for simple pick and place applications, whereas it would be of very little use in advanced visual inspection or gluing applications, for example.
Even if you’ve selected the right type of robot, specific capabilities such as payload, speed, and reach can vary, adding another layer of complexity to the decision-making process.
Failing to select an adequate robot for your application can have several negative effects, including:
Unnecessary spending, especially if an entirely new robot needs to be purchased
Inefficient performance compared to better-suited solutions
Decrease in product quality depending upon the application
How to fix it! Feasibility tests are an excellent method of catching any issues with a chosen robot before making a final purchase. Working with a provider that offers free or low-cost testing is the easiest and most cost-effective way to achieve this.
3. Overcomplicating the process too early
The misconception that the more complicated automation is, the better or more effective it will be, is a dangerous one. It can lead to designers trying to overcomplicate what should be a relatively simple automation project or jump straight to automating the most complicated process available.
Overcomplicating your project can lead to:
Slower return on investment
Overspending on unnecessary hardware & software
Delays in implementation and failure to meet deadlines
How to fix it! Working with an experienced integrator can help keep a project streamlined and avoid overcomplication. Starting off with a relatively simple task and learning from that to work up to more complicated automation is another reliable way to avoid overcomplication.
“We often see customers try to automate everything at once. While this is a noble goal, we generally advise caution. Start simple, make it successful, and expand your initiatives following those successes."
4. Ignoring your current process
It’s easy to see automation as a silver bullet that can instantly make your workflows faster and more efficient. However, automation amplifies your current process, both the good and bad. If you have existing inefficiencies or bottlenecks, automation will simply make these more severe.
Failing to address your current process before automating can lead to several negative impacts:
Wasted time, money, and effort due to inefficiencies
User frustration leading to resistance and decreased adoption
Limited ROI compared to the full potential of automation
How to fix it! Addressing existing bottlenecks and unnecessary steps before automating your workflow will help prevent severe hangups and keep things running smoothly as throughput increases.
5. Overlooking stakeholder inclusion
It’s easy to overlook key stakeholders in automation projects, especially at organizations with clear divides between departments and a lack of interdepartmental communication. However, this can severely hinder implementation.
Different stakeholders will each provide unique perspectives to the project and consider elements that may go unnoticed otherwise.
Failure to bring in all relevant stakeholders can result in:
Avoidable mistakes being made
Minimal understanding of the automation process company-wide
Failure to address concerns about autonomy and job security
How to fix it! Avoiding this pitfall is as simple as establishing a cross-functional team consisting of all key stakeholders — from IT and management to warehouse and operations staff. This will enable more effective communication between the entire company about the project and prevent oversights that could impact implementation.
6. Underestimating upfront costs
While low-cost automation is a rapidly growing field, automating a process can still be an expensive undertaking. While most budgets will take into account long-term costs such as maintenance and personnel training, upfront costs can quickly accrue.
Besides the cost of a robot itself, there are additional costs like accessories (sensors, vision systems, 7th axis units, integration support, and software that can add tens of thousands of dollars to the initial cost of an automation project.
Underestimating the upfront costs of automation can lead to:
Unfinished projects if funding runs out completely
Spending more than planned on the project
Negatively impacted ROI
Delays in the project timeline
How to fix it! Working closely with an integrator to understand every element of the system before implementation is essential to avoiding unexpected costs early. Starting by automating simple processes can also help keep solutions more affordable.
7. Skipping proper training
Just because a process is automated doesn’t mean humans are not necessary. There will likely still be frequent interaction between worker and machine — think day-to-day operation, maintenance, and adjustments — and these workers need to be adequately trained on how to safely and effectively perform new responsibilities.
Poorly trained employees can result in:
Frustration for workers if they can’t perform job tasks
Safety risks if workers aren’t aware of best practices for safety
A need to bring in costly specialists to perform key functions
How to fix it! Taking the time to fully educate employees on new processes and standards will help avoid this pitfall and help garner more employee buy-in, improving both morale and efficiency.
Conclusion
While the hype around automation is greater than ever, and more companies than ever are automating, it’s far from a walk in the park. With 73% of automation projects failing to achieve their intended ROI, it’s essential to avoid the common pitfalls that lead to lost profits and delays in implementation.
Ready to plan your automation project the right way?
Talk with an RBTX expert to turn these lessons into a plan that actually works for your process and budget.