6 Steps to Automating Processes to Meet Business Goals

By Eric Binning, Sr. Enterprise Software Solution Consultant, Rockwell Automation

With the increasing drive to reshore manufacturing operations back to the United States, automation is viewed as a crucial enabler for making domestic production economically viable against offshore alternatives. However, according to Forrester's 2024 Smart Manufacturing Predictions report, implementing software and hardware automation to boost competitiveness in reshored facilities has proven more challenging than expected.

According to the report, one critical factor contributing to this challenge is the difficulty manufacturers face in identifying processes well-suited for automation. The first step is to identify the right processes to automate, but it's often easier said than done.

As reshoring gains momentum, optimizing automation will be critical for securing a competitive position in the domestic manufacturing landscape. Manufacturers can overcome the specific challenges in identifying and adapting processes for automation by aligning their automation initiatives with broader business strategies.

Navigating the Complexities of Automation

Manufacturers face several obstacles when identifying areas for automation. These complexities can make it challenging to determine which aspects can be automated without sacrificing quality or flexibility. Consider these examples:

• Stringent Regulatory Guidelines. In the pharmaceutical industry, for instance, manufacturing processes must adhere to stringent regulatory guidelines to ensure product safety and efficacy. Automating such processes requires a nuanced approach to preserve compliance while still benefiting from automation.
  
  
• Customer Demands. Similarly, in industries such as automotive and food and beverage manufacturing, where customer preferences play a pivotal role, processes often involve a high degree of variability and customization. Automating these processes without sacrificing the ability to cater to diverse customer demands can be challenging.
  
  
• Proprietary Processes or Legacy Equipment. Another challenge arises when processes have been developed in a nonstandard manner because of existing systems and equipment. These processes often rely on manual intervention or inconsistent data, making them harder to automate.

For example, a manufacturing plant with legacy equipment might require operators to manually adjust settings or input data, leading to variations in the process. Standardizing these processes and ensuring consistent data collection is crucial before automation can be successfully implemented.

• Cost Justification. Cost justification is another critical challenge. Manufacturers must develop realistic estimates of the potential benefits associated with automation, including projected productivity gains, quality improvements, and reductions in labor or maintenance costs. The cost of implementing a flexible automation solution may be difficult to justify if the projected productivity gains are marginal or if the system requires frequent retooling that causes extended periods of downtime.
  
  
• Employee Training. Manufacturers must also consider the human element when identifying processes for automation. Employees might fear that automation will lead to job losses, and they may be resistant to learning new skills or adapting to new processes.

Developing a change-management strategy is vital to address these fears. This may include upskilling or reskilling strategies to ensure that employees are prepared for new roles and responsibilities in an automated environment.

As manufacturers navigate these complexities, they must strike the right balance between process optimization, cost-effectiveness, effective change management and adherence to quality standards and customer requirements.

Aligning with Business Strategy

To effectively align automation initiatives with overarching business objectives, take a strategic approach that considers the following key factors: