The main point
Return is not only labour removed. Automation can create capacity, reduce giveaway and rejects, improve consistency and reduce manual handling—but it also adds changeover, maintenance and support costs.
Automation Machinery
See the machinery and application options most closely matched to this production question.
1. Measure the current process
Record labour by task. This should be recorded in the customer requirement so it can be tested rather than assumed.
- Record labour by task
- Measure good output, waste, downtime and overtime
- Identify lost sales or subcontract cost caused by limited capacity
2. Model the future process
Use sustained output after changeover and cleaning. This should be recorded in the customer requirement so it can be tested rather than assumed.
- Use sustained output after changeover and cleaning
- Include remaining operators and material replenishment
- Include maintenance, spares, utilities and training
3. Value the benefit
Calculate labour redeployment, capacity, waste and quality benefit. This should be recorded in the customer requirement so it can be tested rather than assumed.
- Calculate labour redeployment, capacity, waste and quality benefit
- Separate hard savings from possible commercial upside
- Include risk reduction only where it can be supported
4. Stress-test the decision
Model low, expected and high demand. This should be recorded in the customer requirement so it can be tested rather than assumed.
- Model low, expected and high demand
- Allow for ramp-up and downtime
- Check whether a smaller phased investment gives a better return
Customer comparison table
| Benefit or cost | Evidence |
|---|---|
| Labour | Measured time by task and realistic redeployment |
| Capacity | Good packs per scheduled hour |
| Waste | Product and packaging loss per good pack |
| Ownership cost | Maintenance, spares, utilities and training |
| Commercial value | Demand that can actually be served |
Relevant Lancing routes
Use the guide to prepare the requirement, then continue to the specialist routes below.