Authors: Stephen Smiley, Colin Wilson & ChatGPT
Automation has transformed the landscape of manufacturing, promising increased efficiency and precision, as well as reduced costs. However, beneath the surface of these advantages lie potential pitfalls that can derail automation projects. We’ll explore three reasons why an automation initiative in manufacturing may face challenges and how companies can navigate these pitfalls.
1. Inadequate planning and foundational work:
One of the primary reasons automation projects stumble is inadequate planning and ignoring process improvement best practices. Rushing into automation without a comprehensive understanding of the existing processes and a clear roadmap can lead to misalignment between technology and operations. Lack of coordination with different departments and insufficient training for the workforce can result in resistance to change. Successful automation requires meticulous planning, including thorough process mapping, technology assessment and a well-defined integration strategy to ensure seamless collaboration between automated systems and human workers.
Pitfall solutions:
• Value stream map — Evaluating the process flow to identify waste and opportunities for improvement to streamline the process
• TWI job instructions & standard work — Processes need standard work and methodologies; lack of standard work can cause waste and decrease productivity, and using standard work instructions can help the manufacturing process be more effective
• Operational Excellence Best Practices — The foundational work upon which can be built
• Project Definition & Management — Using a project charter to define the project scope, steps and responsibilities
2. Technology limitations and complexity:
While the allure of cutting-edge technology is strong, it’s crucial to acknowledge the potential limitations and complexities associated with it. Adopting overly sophisticated automation solutions can lead to unforeseen challenges. Integration issues, software bugs and the need for constant maintenance can disrupt production schedules. It’s essential for companies to strike a balance between adopting advanced technologies and ensuring that the chosen automation tools align with the specific needs of the manufacturing process. Regular updates, training programs and continuous monitoring can help mitigate the risks associated with technology limitations.
Pitfall solutions:
• Risk management – Assessing the risk of a potential project and planning mitigation strategies to manage the risk; this includes initial engineering development testing to validate risky technologies and developing vendor standards
• Automation skill set assessment — Identify skills required to support the technology, assess employee aptitude, and identify required training to bridge any gaps
3. Resistance to change and workforce adaptation:
Perhaps one of the most underestimated challenges in automation is the resistance to change from the existing workforce. Automation often brings about a fear of job displacement, and employees may be hesitant to embrace new technologies. To overcome this hurdle, companies must invest in effective change management strategies, including communication, training and re-skilling programs. Involving employees in the automation process, highlighting the benefits and demonstrating how automation can enhance their roles can foster a positive attitude toward change, ensuring a smoother transition and long-term success.
Pitfall solutions:
• Change management — Significant initiatives need a change management program to help employees through the change process; 60% of projects fail due to a lack of managing change
• Frontline leader skill development — Frontline leaders have a dramatic effect on employees’ understanding and adoption of major initiatives; good frontline leaders can help employees through the change process
• TWI job instructions & standard work — Processes need standard work and methodologies, as lack of standard work can cause confusion and frustration on the shop floor; using standard work instructions can help employees be more effective
• Blended learning & training — Using online and in-person training can educate employees on automation and project management, as well as reinforce the change process; this knowledge will increase success of projects and reduce employee frustration
In conclusion, while the benefits of automating manufacturing processes are significant, it’s essential for companies to approach automation projects with caution and strategic planning. Addressing issues related to planning, technology integration and workforce adaptation will pave the way for successful automation initiatives, ensuring that the promise of increased efficiency and productivity is realized without succumbing to potential pitfalls.
Stephen Smiley, Business Transformation Service Line Leader
Stephen is a seasoned executive leader specializing in visionary strategy development and practical implementation, driving success across organizations. With a robust background in international, multi-facility operations, he guides teams toward operational excellence and strategic alignment. Stephen’s leadership extends across various industries, including heavy equipment, consumer products and aerospace.
Colin Wilson, Service Line Leader — Senior Consultant Automation Services
Colin’s experience in automation spans nearly two decades. His roles have included component selection/sizing, field service, applications development for custom equipment, and technical system sales for a component manufacturer. Colin has worked with small manufacturers just starting down the automation path, through multinational corporations optimizing their value stream.
Who is WMEP Manufacturing Solutions?
WMEP Manufacturing Solutions is dedicated to the growth and success of small and mid-sized Wisconsin manufacturers. As a private non-profit organization, our mission is entirely centered on driving positive results for our clients. Each year, our team of manufacturing experts collaborates with hundreds of manufacturers, working closely with them to design and implement effective solutions that tackle their most pressing challenges. With decades of industry experience, a wide range of services and a deep passion for manufacturing, we consistently deliver a high return on investment for our clients.
WMEP Manufacturing Solutions is part of the MEP National Network™, a public-private partnership that advances U.S. manufacturing. MEP Centers are located in all 50 states and draw on the talents of more than 1,400 trusted advisors and experts.
On every client engagement we are evaluated on the results we produce, as well as our client’s satisfaction with our services. We are very proud to be excelling on both metrics. Since 1996 the WMEP has assisted more than 4,000 SMMs, resulting in $6.48 billion in economic impact and 26,518 jobs that have been created or retained. In 2023 alone, WMEP helped Wisconsin manufacturers generate $1.01 billion in economic impact, with 1,474 jobs being created or retained.
Company: WMEP Manufacturing Solutions
Innovation: Automated manufacturing processes
www.wmep.org
