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.
- 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
- Bottlenecks, Queues, and Handoffs
When product flow repeatedly stalls between processes, automation can help stabilize movement and improve overall throughput.
- 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
- Repeating Unplanned Downtime
Frequent adjustments, startup delays, or repeated parameter tweaks may signal opportunities for automated controls or feedback loops.
- 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.
