Direct answer
Target the highest fully loaded labour cost per unit on repetitive tasks with stable volume, and build the case on total cost including rework, absence cover, recruitment and injury risk.
How this problem shows up
- Recruitment or retention difficulty on specific shifts
- High agency or overtime dependency
- Manual tasks with ergonomic or safety exposure
- Quality varies with operator experience
- Labour cost per unit rising faster than volume
Engineering responses
Automate the heaviest repetitive task
Palletising, machine tending, packing — typically the fastest payback.
Semi-automation
Machine handles the physical burden, operator retains judgement.
Line rebalancing
Redistribute work content before adding machines.
Redeployment planning
Move displaced labour to quality, maintenance or new capacity.
Engineering and project considerations
- Fully loaded labour cost includes benefits, absence cover, recruitment, training and turnover
- Automation adds maintenance and engineering cost — model the net
- Local labour regulation and works council consultation timelines
- Skills upgrade required to support automated equipment
- Payback should tolerate a demand downside scenario
What to prepare before engaging engineering companies
- Fully loaded labour cost per station
- Time study or cycle data per manual task
- Volume forecast with downside case
- Maintenance capability assessment
What to measure
Frequently asked questions
What payback is acceptable?
Industrial automation is commonly sanctioned between 18 and 42 months depending on volume certainty and cost of capital. Shorter is not always better if it points to an under-scoped solution.
Does automation always cut headcount?
Often it converts direct labour into technical roles rather than removing it. State this clearly in the business case.
Related engineering knowledge
Independent, buyer-side and supplier-neutral
Global B2B Group does not sell machines and does not represent equipment manufacturers. This material is published to help industrial organisations define the problem, prepare the specification and structure the investment before engineering partners are selected.