Why is Automation So Hard - Part 3 - Where Automation Fails First
Most automation failures don’t come from bad hardware—they come from inside the factory walls. Here’s how to fix misalignment, shifting specs, and ROI blind spots before they ruin your investment.
Why Internal Misalignment and Shifting Specs Kill More Projects Than Technology Ever Will
The Problem Isn’t the Robot. It’s the Room.
When automation projects fail, the blame often lands on the integrator or the technology itself.
But in our experience?
The real failure happens before the equipment is even installed.
It happens:
In conference rooms where leadership and operations aren't aligned
In product meetings where specs shift weekly
In procurement conversations that prioritize short-term savings over long-term value
And in plants where support for the system ends the day it's powered on
This is where automation fails first—not in the hardware, but in the handoff.
1. A Limited View of ROI Kills Momentum
Automation can offset labor costs—but that’s not enough.
What rarely gets factored into the ROI calculation:
Reduced injury claims and repetitive motion issues
Improved sanitation and food safety
More efficient retention and onboarding
Line flexibility and data visibility
High-quality employees aren't replaced by automation.
They're empowered to add more value, manage more responsibility, and elevate operations.
If your automation pitch only focuses on headcount reduction, you're selling it short—and likely underfunding it, too.
2. Shifting Specs, Missed Conversations
The system is specced to run Product A.
Six weeks before install, Product B is added—different size, box, specs.
Now the automation can’t keep up. It gets blamed.
These problems aren’t just technical—they’re cultural.
Automation success requires:
Clear communication between departments
Buy-in to design for flexibility, even when it adds cost
Authority to invest in adaptability before it becomes an emergency
3. You Can't Set It and Forget It
Automation is not magic. It’s machinery.
It needs:
Preventive maintenance
Software updates
Performance tuning
Ongoing training and OEM support
At Next Tech, we design service into the system.
Quarterly visits. Remote diagnostics. On-site optimization. Because good systems require great care.
4. Think Bigger Than One Plant
One of the best shifts we’ve seen?
Solve the problem globally—not just locally.
If the same product runs in multiple facilities, build the system once—and replicate it with precision.
Yes, the first system costs more. But:
Standardized systems reduce complexity
Shared service playbooks reduce downtime
Documentation and functional blocks scale easily
The Bottom Line
Most automation doesn’t fail because of the robot.
It fails behind closed doors—where specs drift, goals misalign, and support stops too soon.
We help our customers fix that, from day one.
Why is Automation So Hard - Part 2 - The First System Problem
The first automation system is always the hardest—both for the manufacturer and the integrator. Here’s how to avoid getting stuck with a one-off machine and start building for repeatability from the start.
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?
Struggling to automate your operations? This series explores the root causes of failed automation projects—and how manufacturers can do it right.
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.