When does factory automation actually pay for itself?

Automation is capital. The question is not whether a robot can do the task — usually it can — but whether the payback period is short enough to justify the machine.

Start with cycle time and labour cost per unit. Multiply by annual volume. If the annual saving does not clear the machine cost within roughly two to three years, the case is weak unless quality or safety is the real driver.

Quality and consistency often matter more than labour cost. Rejection rates that drop from 6% to under 1% can justify a station on their own.

Consider variability too. A high-mix, low-volume line needs flexible tooling and quick changeover design, which raises the cost of the machine but keeps it useful.

We design special purpose machines, conveyors, pick-and-place stations and robotic cells from concept through to the manufacturing package — and will tell you honestly when a simple jig would serve you better than a robot.

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