Why is Automation So Hard - Part 3 - Where Automation Fails First
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.
