Listado de la etiqueta: Manufacturing Automation

The Real Cost of Automation: Planning for Long-Term Success

While the benefits of automation are well recognized, financial considerations remain one of the largest barriers to adoption. According to industry research, 32% of manufacturers identify lack of budget as a primary obstacle. However, the issue is often not the cost itself, but the miscalculation of the Total Cost of Ownership (TCO).

The initial investment in advanced systems is only part of the picture. Companies must also consider integration costs, downtime during installation, and the need for training or external consultants. Failing to account for these factors can compromise project viability before implementation even begins.

A comprehensive financial framework should include:

  • Planning and development – Feasibility studies and technical evaluations.

  • Acquisition and integration – Hardware, software, and process alignment.

  • Maintenance and upgrades – Sustaining efficiency over time.

  • Retirement or replacement – Anticipating the lifecycle of the technology.

Complementing this with a full risk assessment provides a safety margin for unforeseen challenges. Building financial resilience is essential, as unexpected issues can arise at any stage of the project.

The lesson is clear: a delayed but well-planned automation investment is far more sustainable than an accelerated one lacking financial clarity. By taking a holistic approach, manufacturers ensure that automation delivers not only immediate gains but also long-term profitability.

📖 Inspired by Nicolas Lachaud-Bandres, Hexagon Manufacturing Intelligence.

Overcoming Integration Challenges in Manufacturing Automation

Manufacturing automation has become a strategic advantage for companies across diverse industries, from automotive to ceramics and food production. Beyond efficiency gains, it is a transformative process that optimizes entire production lines. However, one of the most significant challenges in adopting automation is the integration of new technologies with existing infrastructure.

Many organizations underestimate the complexity of aligning advanced automation systems with legacy equipment, software, and factory layouts. Incompatibility may arise in several forms: from differing operating systems and protocols to physical limitations on the shop floor. These obstacles often lead to delays, unexpected costs, and frustration if not addressed early in the process.

To overcome these barriers, companies must adopt a structured approach:

  • Conduct a thorough system audit. Understanding current tools, processes, and technologies is essential before investing.

  • Select the right vendor. A partner with proven industry expertise ensures smoother integration and provides critical training and support.

  • Engage technical teams from the start. IT and engineering departments bring essential perspectives and technical knowledge to anticipate and mitigate compatibility issues.

When properly managed, integration is not a limitation but an opportunity to maximize efficiency and maintain competitiveness in a rapidly evolving industrial environment.

📖 Inspired by Nicolas Lachaud-Bandres, Hexagon Manufacturing Intelligence.

What is Change Management?

To begin, it is essential to align on what we mean by Change Management.

The Project Management Institute (PMI) defines it as:

“Change management is the organized and systematic application of knowledge, tools, and resources of change that provides organizations with a critical process to achieve their business strategy.”

In the context of organizational change, several models and methodologies can be applied to support transformational initiatives.

One of the most recognized frameworks is the ADKAR Model developed by Prosci. ADKAR stands for Awareness, Desire, Knowledge, Ability, and Reinforcement—five key elements that must be addressed for change to be successfully implemented and sustained.

Practical Examples of Change Management in Action

  1. Transitioning from manual inventory management to an automated system.

  2. Implementing new technologies, such as a CRM platform.

  3. Redesigning digital communication strategies.

  4. Introducing an AI-powered chatbot.

  5. Optimizing communication between project teams.

Change Management is not just about technology—it is about people. Successful transformation requires structured planning, clear communication, and continuous reinforcement to ensure adoption.

Reference: Adapted from The Digital Project Manager