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.
