Why is Automation So Hard - Part 2 - The First System Problem

Why Building It Once Isn’t Enough

This is is Part 2 in a 5-Part Series about automation challenges for manufacturers today. See Part 1 Here.

The Custom Trap

A manufacturer invests heavily in a custom automated system. It’s built to spec, pushed through testing, and installed with the hope that it’ll solve a major bottleneck.

But within months:

• A spec changes

• A product variant is added

• A second system is needed—and no one can quite remember how the first one was built

This is the First System Problem:
The first system works, eventually….(hopefully)

Why the First System Is So Dangerous

Most manufacturers think of the first system as the hard part.
They’re right—but not just for them.

The first system is often the most difficult for the integrator too.

At that stage:

• Functional goals are shifting

• Interfaces aren’t standardized

• Debug time is unpredictable

• And most integrators barely break even

It’s a risky phase, and too often it leads to:

• One-off designs with no clear path to replication

• Poorly documented or “tribal knowledge” systems

• Integrators who don’t go the extra mile—because they can’t afford to

And that’s how automation gets a bad reputation: the next time leadership is asked to invest, they hesitate.

The Key: Build Like You’ll Build Again

The solution isn’t to overspend or overengineer.
It’s to approach the first system like it’s System 1 of 10—even if only one is guaranteed.

At Next Tech, we tackle this by designing with:

• Repeatable functional blocks – proven control and motion components we can adapt to each use case

• Modular frameworks – mechanical and electrical layouts that scale with minimal redesign

• Clear documentation – every wire, program, and panel spec documented from Day One

• A scalable mindset – we make it easy to build System 2–10 faster, cheaper, and with less risk

This reduces the R&D curve without compromising on tailoring the solution to your process.

Why It Matters

When your first system is built right:

• Future builds install in half the time

• Debugging and service are consistent

• Operators and maintenance teams get up to speed faster

• The ROI improves with every system—not just the first

When it’s not?

You’re locked into one system, one vendor, and one painfully expensive refresh cycle.

The Next Tech Approach

We don’t view the first system as a one-time win.
We view it as a launchpad—a foundation for the next five years of your growth.

Our process:

• Reduces unknowns for your team and ours

• Sets a roadmap for follow-on systems

• Helps you sell automation internally with confidence

• And ensures every new system builds value—not complexity

Let’s make sure your first system isn’t your last.
👉 Contact Next Tech to start designing a scalable automation future.

Why Is Automation So Hard?

A Manufacturer’s Guide to Overcoming Key Barriers

The Story Told Thousands of Times

The manufacturing manager told me why their leadership team was hesitant to make another investment in automation:

“The last system we had was so limited in what it could do, we ended up having to bypass it so often that we moved it to storage. We’re getting killed on labor costs and sometimes can’t even run this line due to no-shows—but they won’t invest in automation unless it can do everything we need.”

This story is all too common. Across the industry, operations leaders are stuck in a frustrating loop:

• Labor shortages disrupting production

• Leadership unwilling to reinvest after failed automation projects

• High costs and complexity blocking progress

Meanwhile, profits are sitting idle, frontline teams are overwhelmed, and outdated systems struggle to keep up.

Does it have to be this way?

Why This Blog Series Matters

If you’re struggling to automate, you’re not alone. Automation is hard—but not because the tech doesn’t exist.
It’s hard because of how it's approached.

This blog series reveals the root causes and shows manufacturers how to get it right—through clarity, alignment, and systems that are built to scale.

What to Expect from This Series

Part 1 – Introduction: Why Is Automation So Hard?
Today’s post outlines the biggest challenges keeping manufacturers from successfully automating their operations.

Part 2 – The First System Problem: Why Building It Once Isn’t Enough
Your first system is the prototype for what comes next. We'll cover how to design for repeatability and long-term ROI.
(Read more from Automation World)

Part 3 – Inside the Factory Walls: Misalignment, Variability, and Why Automation Fails Internally
Internal politics and ever-changing product specs kill automation faster than any robot glitch. Learn how to overcome both.

Part 4 – The Tech Trap: AI, Vision, and the Seduction of “Smart” Solutions
Before you chase the latest AI solution, make sure your foundations are solid.
(More insights at TechTarget)

Part 5 – What Good Automation Looks Like: Simple. Scalable. Strategic.
Real-world examples of automation done right—and what you can learn from them.

Let’s Build the Right System Together

Frustrated by past automation failures—or unsure where to begin?
👉 Let’s talk. We’ll help you find the next right step, not just the next big investment.