Why Is Automation So Hard?

Written By Zack Lynch

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Meanwhile, profits are sitting idle, frontline teams are overwhelmed, and outdated systems struggle to keep up.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

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