Blog

Why Manufacturing Needs Outside Automation Help

Manufacturers need outside guidance with automation because the industry keeps changing. Technology moves fast. Skills and knowledge can get outdated. The way factories run in 2025 is not what it was ten, even five years ago. Robots, sensors, software, and entire systems all move quickly. That is the main reason many have decided to bring in an Automation Consultant.

You can try to figure things out yourself. Maybe you even have a smart internal team. But the learning curve is steep and mistakes can be expensive. Consultants see patterns. They save time and help you avoid traps others have already hit.

Does every factory manager need one? Maybe not, but the cost of being left behind is getting high. I think it is worth discussing why this role has become standard in manufacturing.

What an Automation Consultant Actually Does

Some people hesitate when they hear the word “consultant”. Is it just paid advice? That is not quite right in this context.

Tasks You Can Expect

• Analyzing your workflows and equipment
• Spotting disconnects between systems or departments
• Evaluating your current software and machine setup
• Proposing how to combine hardware and software in smarter ways
• Guiding your team through upgrades or new rollouts
• Training your workers so results actually stick

It still surprises me how often manufacturers think of automation as just “getting robots.” The reality is much wider. It might include barcode readers, process analytics, dashboards, data gathering tools, sensor systems, or simple workflow edits that do not involve any machinery at all. Sometimes it is mostly software.

“Automation consultants do more than sell you on new equipment. They help you choose what fits, so you do not waste money or create new problems.”

I once watched a mid-sized factory in Ohio buy a six-figure robot arm that ended up sitting idle. Nobody had mapped out the workflow. A consultant can keep you focused on practical changes, not just shiny purchases.

Why Internal Teams May Struggle

People like to trust their teams. But internal staff can only know what they have seen. That can cause blind spots.

Some reasons this happens:

• People are busy with daily problems. Big changes get pushed to the side.
• They are used to how things have “always been.”
• Specialized knowledge required can vary a lot. One week it is PLC programming. Next, it is cloud data flows or IoT security.
• Upgrading means risk. It’s hard to try new things when you fear stops or downtime.

An outside consultant brings a bigger field of vision. They have watched dozens of lines, not just your own.

“Consultants bring the outside pressure to push a team forward, but also share real stories from other plants. Lessons that you would not get by reading a manual.”

I often hear from engineers who were stuck in the weeds. Someone from outside showed them a workaround or system they had not heard of. Sometimes the answer is surprisingly simple, and the outside voice makes it clear.

How Automation Consultants Add Value

Sometimes the impact is direct. Costs drop or output goes up. Other times, the results are less obvious at first.

Here are some areas to consider:

Area	How a Consultant Helps	Example
Equipment Choice	Avoids overspending and mismatch	Choosing sensors that match your actual needs, not marketing promises
Connectivity	Makes old and new machines “talk” to each other	Integrating a new bottling line with an existing warehouse management system
Process Analysis	Finds hidden delays or weak points	Spotting idle times that add up to lost hours per week
Training	Shows your team how updates work in real settings	Hands-on demos for new touchscreen interfaces
Project Management	Keeps upgrades on track and budget	Phasing rollouts to avoid long shutdowns

The right consultant does not just point out what is “wrong.” They see what is working already, and protect what you have built.

When Should You Bring in Help?

You do not always need a consultant every time you buy a conveyor or new PLC. Some triggers make bringing in outside expertise worthwhile.

• You are considering a major upgrade or a new line
• Your output has stalled (or errors are creeping up)
• You need to connect software and machinery that normally don’t “talk” to each other
• Your staff spends too much time resolving the same recurring issues
• You want to train workers on new tools but lack in-house experience

Looking back, a friend in Pennsylvania told me that the best change his team made was asking for help sooner. His words stuck with me — “If I had waited, we would have kept fixing the past instead of building for the future.”

“Delay usually costs more than early advice. Most factories discover this the hard way.”

Choosing the Right Consultant

Not all consultants are the same. Some have broader technical backgrounds. Others have hands-on experience in specific industries.

I always recommend asking:

• What experience do you have with companies like ours?
• Can you show examples of your work? (Not just big names, but projects similar in size and scope.)
• How do you measure project success?
• Will you handle training or just make recommendations?
• How do you approach costs and returns? Is the focus practical?

Sometimes you may not even know what kind of help you need. That is normal, and a good consultant will help clarify that. Be wary of anyone who only pushes for big, high-cost solutions.

Common Challenges and Pitfalls in Automation Projects

Even with good consultants, factories can hit roadblocks. Here are a few I have seen (and heard plenty about):

• Trying to automate broken processes, which just leads to automated waste.
• Ignoring worker input — the people operating the machines spot issues before management does.
• Poor change management; not everyone likes new tools appearing out of nowhere.
• Expecting overnight results. Actual payback may take months, sometimes longer.

It is easy to think hiring a consultant will “fix everything.” It rarely works that way. But if you are open and realistic, gains do show up and tend to compound over time.

Does the Size of the Operation Matter?

There is a belief that automation consultants only help large companies. That may have been partly true before. But these days, even small manufacturers face overlapping tech and compliance needs.

A ten-person shop may not need a full year-long engagement. Shorter projects still pay off — for example, a review of order tracking or shipping processes.

The point is: size does not rule out the value of help. Sometimes it is the small or medium-sized places that benefit most, since large operations may move too slowly or have layers of approval.

Benefits You Can Measure (and a Few You Might Overlook)

It is easy to predict fewer errors. Or more output. But some effects sneak up on you.

• Less scrap, less downtime
• More accurate reporting
• Improved scheduling (saving OT costs)
• Less stress when something breaks down
• Cleaner data to inform other business decisions
• More confidence for workers, who stop dreading each software update

A manager I spoke to said automation training helped his team start “asking better questions.” That is not a number you can put in a report, but it matters.

Automation Trends to Watch in 2025

Looking around at plants and trade shows, I see these as the main things shaping the current conversation:

• Affordable robotics
• Cloud-based monitoring (more data, right from your phone or laptop)
• Simple integration tools — moving data across platforms without much coding
• Real-time analytics and preventive maintenance alerts
• AI-powered inspection tools

Some of these trends are still early. You might get different advice from different experts. That is normal; the field is crowded. The challenge is figuring out which tools will actually help your factory run better in daily practice.

How to Work with a Consultant

You may already have someone in mind, or maybe you are just starting the search.

A practical suggestion: do not expect perfection on day one. No one has a crystal ball. Instead:

• Be clear about your goals (even if they are rough at first)
• Keep communication regular and open, even when things hit bumps
• Ask for plain language explanations, not jargon
• Involve your “on the ground” team in conversations, not just managers
• Start with a pilot area if the project is big — see results before scaling out

Most consultants will ask a lot of questions at first. That is a good sign. The right answer might not match your original vision, and that is fine. Sometimes the best results come from shifting plans based on what is really happening, not what was expected.

What About Cost?

Some companies get stuck here. It can feel like “one more expense.” But try to compare real costs.

A simple table shows this:

Upfront Cost	Long-term Savings
Consultant fee	Faster upgrades, fewer mistakes, smoother adoption
No consultant, DIY approach	Possible missed steps, longer learning curve, more trial/error costs

Is it always worth it? Not every time. Some small fixes or changes you can make yourself. But as soon as a project touches multiple teams, systems, or large investments, outside help usually leads to saving money and time in the end.

My friend told me his factory once spent more on fixing mistakes from a botched automation upgrade than they would have on hiring a consultant upfront.

Common Misconceptions

Some thoughts get repeated, maybe too often:

• “Our people are smart; we do not need outside help.” True, but blind spots are real.
• “Consultants just tell you what you already know.” Sometimes, but often they spot things missed for years.
• “Automation puts people out of work.” Yes, jobs do change. But most shops find that investing in upskilling leads to better retention and happier teams.
• “We are too small to benefit.” As mentioned earlier, even smaller companies can see real advantages.

Being cautious is not the same as being resistant to new ideas. It is normal to worry about cost, disruption, or culture shifts. But waiting often costs more, and the trend in manufacturing is not slowing.

What Does a Good Automation Consultant Look Like?

Here is what to look for based on experience and mistakes I have seen:

• Technical knowledge in manufacturing (not just IT or software)
• Good listener — understands what you want before suggesting solutions
• Clear communicator (avoids buzzwords)
• Realistic; admits when something will take time or may not work perfectly
• References from similar projects
• Willing to say “no” if something is not worth doing

Getting the right match is a process. Expect some back-and-forth. If a consultant promises the moon, be wary. Honest discussions save trouble later.

Are There Risks in Hiring Consultants?

Like any outside partner, there is risk if you are not involved or communicate badly. Common troubles:

• Scope creep — the project keeps growing. Set clear goals.
• Lack of follow-up after launch. Good consultants check in.
• Choosing a “big name” who sends in a junior instead of the expert you expected.

Do your background check. Talk to people who worked with this person or company before. Cheap now can cost more later if the fit is wrong.

Do You Always Need a Consultant?

Sometimes, you do not. If your project is small, your team is experienced, and your workflow is simple, it might not be worth the cost.

But conditions change every year. New regulations, new supply chain problems, new customer deadlines — these keep arriving. Automation keeps expanding. If you do not review your systems every couple of years, you will fall behind even if you did everything right in the past.

What Questions Should You Ask Before Starting?

Factories often ask a lot about technology and price. Both matter. But I would urge you to ask these as well:

• What is the biggest win I can expect in the first three months?
• If things do not go as planned, how do we fix it?
• How will you teach my staff to handle the new setup?
• What is the total cost, including possible overruns?
• How much of my time (or my team’s) will be needed for success?

One Last Example: Missed Opportunity

A small plant in Indiana ignored outside advice and bought new machines without an expert review. Six months later, those machines could not talk to their old ERP system. Fixing it cost more than getting good advice at the start.

Things like that happen every year. The lesson is not “always hire a consultant.” It is to pause and ask if you can benefit from extra guidance before making expensive changes.

Question & Answer

Q: Is automation really necessary for every manufacturer right now?
A: No, not every single one. Some can get by without major changes for a while. But more and more, customers and suppliers expect faster turnaround, less waste, and better data. So even companies that feel safe now could face tougher pressure soon.

The real question you might ask: How much risk can you handle if you do nothing? Is it more, or less, than the cost of bringing in expert help?

As a manager said to me last year, “Our competitors use consultants. Ignoring them did not make us smarter; it made us slow. I do not want to be slow again.”

What holds you back from considering an outside perspective? Sometimes just questioning that is the best first move.