Fit for Purpose: Selecting Automation Wisely – When to Automate, When to Hold

Insights from a webinar presented by Technical Specialist Jeremy Smith, Illinois Manufacturing Excellence Center

Automation is everywhere in modern manufacturing conversations. Collaborative robots. Smart sensors. AI-driven systems. Integrated cells that look flawless on the trade show floor.

They’re exciting. Powerful. Impressive.

But there’s a hard truth many manufacturers eventually encounter:

Not every problem deserves automation.

In a recent webinar hosted by the Illinois Manufacturing Excellence Center (IMEC), Technical Specialist Jeremy Smith explored a deceptively simple question:

How do we make sure we’re automating the right things for the right reasons?

The answer begins not with technology, but with problem definition.

The Automation Trap: Falling in Love with Solutions

Manufacturers are constantly exposed to new tools and systems:

• A supplier demonstrates a sleek automation cell
• A peer company shares a success story
• A trade show unveils the “next big thing”

The natural reaction?

“Where could we use that?”

Jeremy refers to this as solution-first bias; starting with a technology and searching for a problem to justify it.

The Risks of Solution-First Thinking

• Investing in solutions that don’t address your biggest constraints
• Expanding project scope without clear boundaries
• Struggling to prove return on investment
• Ending up with “orphaned automations” — expensive equipment sitting idle

Instead, high-impact automation efforts move in the opposite direction:

Define the problem first.

Why Problem Statements Matter More Than You Think

A clearly framed problem statement does more than document an issue. It becomes the foundation for:

• ✅ Alignment across operations, maintenance, engineering, and safety
• ✅ Measurable success criteria
• ✅ Controlled project scope
• ✅ Faster vendor and integrator engagement
• ✅ Reduced redesign and rework

Without clarity, automation projects often drift into local optimization, improving isolated steps while leaving overall throughput unchanged.

As Jeremy noted:

“We may just end up making waste faster.”

The SMART Framework for Manufacturing Problems

Strong automation projects begin with strong problem statements. Jeremy recommends using the SMART framework:

• Specific – Identify exactly where and what the issue is
• Measurable – Establish a baseline and define a target
• Achievable – Stay within realistic constraints
• Relevant – Tie directly to business performance
• Time-Bound – Define when success should occur

Example: Vague vs. Precise Framing

❌ “We have quality issues in casting.”
✅ “Temperature variance on Casting Line A is causing missed pours in Cores 12–18.”

Specificity immediately sharpens investigation, solution design, and evaluation.

Identifying Automation-Worthy Pain Points

Once a problem is clearly defined, the next question becomes:

Is automation the right type of solution?

Certain patterns strongly indicate strong automation candidates.

1. High-Volume, Rule-Based Work

Tasks that follow consistent logic and repeat frequently are prime targets:

• Repetitive handling or assembly steps
• Deterministic inspection criteria
• Predictable machine interactions

1. Bottlenecks, Queues, and Handoffs

When product flow repeatedly stalls between processes, automation can help stabilize movement and improve overall throughput.

1. Manual Data Capture

Clipboard-to-computer workflows are classic opportunities for sensors, system integration, or digital tracking.

Benefits may include:

• Reduced labor
• Improved accuracy
• Real-time visibility

1. Repeating Unplanned Downtime

Frequent adjustments, startup delays, or repeated parameter tweaks may signal opportunities for automated controls or feedback loops.

1. Traceability and Compliance Challenges

When documentation depends heavily on human consistency, automated capture and logging can dramatically improve reliability.

A Practical Way to Prioritize Automation Ideas

Even with strong candidates identified, resources are finite.

Jeremy recommends a simple qualitative triage model using two dimensions:

Value Signal (1–5)

How strongly will this solution impact key KPIs relative to cost?

• 1 = High value, low cost
• 5 = Low value, high cost

Effort Signal (1–5)

How difficult is implementation?

• 1 = Low effort
• 5 = High effort

Prioritization Score

Value × Effort

• Low scores → Strong candidates
• High scores → Weak candidates

This lightweight method helps teams apply structured thinking without slowing momentum.

The Critical Constraint Check

Before acting on rankings, one more filter is essential:

Can we sustain this solution operationally?

Ask:

• Do we have maintenance capability?
• Are spare parts accessible?
• Does it introduce hidden dependencies?
• Does it align with future production needs?

Even high-value ideas may be disqualified by operational realities.

Right-Sizing the Automation Intervention

Automation decisions should never focus solely on current pain.

Effective strategies consider:

• Expected growth
• Product mix evolution
• Workforce implications
• Long-term scalability

The goal is not just solving today’s problem — but avoiding tomorrow’s replacement project.

Closing the Loop: Measuring Real Success

Automation is not complete at installation.

Sustained improvement requires:

• Defined KPIs
• Regular review cadence
• Validation against original SMART targets
• Monitoring for regression

Without follow-through, even well-designed systems can fail to deliver lasting business impact.

Ready to Make Automation Work for Your Business?

Automation should be a business decision first — grounded in operational need, financial impact, and long-term strategy.

If your organization is exploring automation but wants to ensure you’re solving the right problems first, IMEC can help.

Our team works alongside manufacturers to:

• Clarify and frame operational challenges
• Evaluate automation readiness
• Prioritize opportunities with measurable ROI
• Reduce risk before capital investment

Start with a conversation.
Connect with IMEC to assess whether your automation initiative is truly fit for purpose — and aligned with your growth goals.

Contact IMEC today to schedule an automation readiness discussion.