Why Manufacturers Need an Automation Strategy and Roadmap, Not Just a Quick Fix

For many manufacturers, automation starts with a single pain point—lifting heavy bags, assembling boxes, or fixing an ergonomic challenge. Those are valid reasons to automate, but as Charlie Motley, WMEP Consultant, warns, stopping there can create bigger problems down the line. “When companies jump straight to a solution without mapping the process, they’re not really starting automation—they’re just solving today’s problem,” he says. “And too often, that solution doesn’t fit with the rest of the operation.”

Step One: Map the Process Before You Automate

When a manufacturer decides to automate, Charlie says the first step is to step back and outline the process. “Write out the process in a flow chart,” he explains. “If you don’t know how the work fits into the bigger system, you might spend money automating something that upstream changes could eliminate altogether.” By mapping processes and looking upstream and downstream, manufacturers often discover opportunities that are more cost-effective and deliver greater impact than the original fix.

Step Two: Make a Plan That Fits the Business

Even when a project seems obvious, Charlie cautions against acting in isolation. “Automation has to fit into your company’s strategy, budget, and facilities,” he says. “If you don’t have buy-in or a plan, you risk spending millions on equipment that doesn’t support your long-term goals.” Charlie encourages companies to think in stages: a three-year plan, a five-year plan, and a flexible roadmap that anticipates future needs. That way, today’s project becomes the foundation for tomorrow’s growth rather than a standalone solution.

Step Three: Build Discipline into the Project

Poor planning often leads to costly surprises: a machine that doesn’t fit in the building, missing safety reviews, the wrong PLC platform, or no spare parts or documentation. To prevent these problems, Charlie recommends a disciplined process:

• Develop a clear RFQ that includes safety standards, controls specifications, and documentation requirements.
• Work with multiple integrators and use design reviews to confirm fit and feasibility.
• Require Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT) to ensure equipment performs as promised.
• Train operators and maintenance teams to keep automation running long after installation.

“Most of the things that go wrong at the end of projects should have been addressed at the beginning,” Charlie says. “When you push all that detail to the front end, you save time, money, and frustration.”

Step Four: Verify Resource Availability and Skill Sets

Before moving forward with automation, it’s critical to confirm that the right people, skills, and capacity are in place to support the project. What experience is needed to manage it? Do those skills exist internally? And do those individuals have the time to dedicate to the project’s success? If not, outside resources may be necessary—whether to fill specialized skill gaps or to provide project management support. Charlie notes this is where many manufacturers stumble. “A lot of small and mid-sized companies don’t have people who can maintain or troubleshoot automation once it’s installed,” he explains. “If you don’t plan for who’s going to keep it running, you risk having a machine that sits idle the first time something breaks.” Ensuring resource readiness up front—both for implementation and ongoing support—helps manufacturers protect their investment and sustain the gains automation is meant to deliver.

Treat Automation as a Growth Strategy

Automation done right is not about dropping in a robot—it’s about building a roadmap. By mapping processes, aligning projects with strategy, and front-loading planning, manufacturers can avoid costly mistakes and create automation systems that deliver lasting value. As Charlie puts it: “Automation should fit your factory like a glove—not land like a rock in the pond.”

WMEP is a nonprofit consulting organization with a simple mission: help Wisconsin manufacturers succeed. Our advisors bring real-world industry experience and deliver practical solutions across three key focus areas: Growth, Operations, and People. Contact us to explore how we can help you approach automation with confidence and accelerate ROI and learn more about our Automation services.