Artificial intelligence (AI) is dominating headlines with its potential to transform the way we work, helping businesses streamline processes, boost productivity, and drive growth. Yet, many organisations still view robotics and automation—widely regarded as precursors to AI and integral to its successful application—as intimidating and complex. These apprehensions are often coupled with long-standing fears of workforce displacement and concerns over the costs and challenges of implementation. The reality is that robotics and automation are no longer optional, particularly in the manufacturing sector. These technologies are critical for businesses aiming to stay competitive and tackle today’s manufacturing challenges. However, understanding where to start and how to integrate new systems effectively is crucial. Equally important is adopting a balanced approach that values human expertise alongside technological advancement. With this in mind, Mark Gearing, R&D Group Print System Director at Domino Printing Sciences, and Peter Williamson, CEO of Automate UK, share insights on getting started with robotics and automation, emphasising the indispensable role of the human workforce. 
Why Invest?
The manufacturing industry is grappling with a significant workforce shortage. A recent report by Deloitte and the Manufacturing Institute estimates that by 2033, the US manufacturing sector could need as many as 3.8 million new workers, with up to 1.9 million roles potentially going unfilled. While it’s true that some roles—or more specifically, certain tasks—are at risk of being replaced by automation and robotics, these are often the most difficult positions to fill. Businesses that resist progress by attempting to preserve such roles risk falling behind. A 2023 report from the Manufacturing Technology Centre highlights this point, noting that UK manufacturers’ reluctance to invest in automation and robotics has had a measurable impact on the nation’s productivity. Crucially, fears of job loss due to automation are increasingly counterbalanced by evidence to the contrary. Rockwell Automation’s recent State of Smart Manufacturing report found that an overwhelming 94% of businesses expect to either maintain or expand their workforce as a result of adopting smart manufacturing technologies. The key takeaway is that people can be upskilled into new roles, while businesses that fail to adapt risk obsolescence. As Max DePree, founder of Herman Miller, aptly put it: “We cannot become what we want to be by remaining what we are.”
Where to Start?
If the ‘why’ of adopting robotics and automation is now beyond dispute, the next question for businesses yet to take the plunge is ‘where’ to begin. A practical approach is to start with the dull, dirty, and dangerous tasks—roles that are challenging for human workers to perform effectively. High on the list are repetitive, business-critical tasks like manual data entry and extraction. These offer little job satisfaction and are easy to automate using smart tools such as coding automation software, which can replicate simple processes with exceptional accuracy. The advantages of automating routine data management are clear. In manufacturing, human error stemming from repetitive tasks like manual code entry can lead to unplanned downtime, increased costs, reduced quality, and wasted resources. A study by Vanson Bourne found that 23% of all unplanned downtime in manufacturing is due to human error. Similarly, repetitive manual tasks such as picking, packing, and palletising are prime candidates for automation through robotic technology. These roles, often difficult to fill, can involve harsh or inhospitable environments and pose risks of fatigue, frustration, and injury. It’s also important to identify areas where automation could have the greatest impact. Tasks requiring precision—where robots consistently outperform humans—are ideal candidates. Examples include automated label applicator adjustments for precise placement or visual quality control. In fact, 45% of businesses in Rockwell Automation’s State of Smart Manufacturing report cited quality control improvement as their top priority for smart systems. Crucially, adopting robotics and automation doesn’t require an ‘all or nothing’ approach. For organisations at the beginning of their journey, starting small is both sensible and strategic. Focus on a specific production issue where automation can provide immediate benefits. Once these are realised, they will justify further investments down the line. Starting on a small scale brings numerous benefits, including minimal capital expenditure, reduced disruption, and increased workplace confidence. However, any investment should align with broader process improvements, considering how individual projects fit into an organisation’s smart systems journey. Whether it’s automating a single workflow, task, or entire process, adaptability and a long-term vision are essential. For those uncertain about where to begin, experienced providers of smart solutions can offer consultancy services to help identify target areas, plan projects, and establish an implementation timeline. Their expertise can be invaluable in guiding businesses through the initial stages of automation.
Collaboration & Continuous Improvement
“Why not make the work easier and more interesting so that people do not have to sweat? The Toyota style is not to create results by working hard. It is a system that says there is no limit to people’s creativity. People don’t go to Toyota to ‘work’; they go there to ‘think.’” – Taiichi Ohno, founder of the Toyota Production System Your workforce is a vital component of your robotics and automation journey, contributing to identifying areas for improvement, shaping technological developments, and driving creativity. Those directly involved in production possess valuable insights into tasks that add little value to their work experience and hinder recruitment or upskilling opportunities. Engaging your workforce in the automation journey not only fosters loyalty but also provides critical understanding for prioritising future investments and fostering continuous improvement. Future investments can also benefit from combining existing workforce knowledge with human analytical and decision-making skills. A best-in-class approach blends the rich production data captured by smart systems with human expertise to generate actionable insights for business growth. It’s crucial to proceed at a measured pace, but as your journey advances, an engaged and empowered workforce will help identify opportunities for further line developments, including potential AI applications. AI adoption can follow a similar incremental approach, starting with targeted improvements such as detecting narrow parameter errors in vision inspection systems or analysing trend data.
Conclusion
As businesses across sectors explore AI applications, manufacturers who have yet to adopt robotics and automation should act now before the opportunity passes. By partnering with agile, adaptable suppliers capable of addressing your business’s unique challenges—whether it’s building a compelling business case, identifying quick wins, developing an automation roadmap, or offering flexible financing—there’s never been a better time to embark on your smart systems journey.
