Lessons Learned from Implementing Mobile Automation
While mobile automation technologies like Autonomous Mobile Robots (AMRs) and Automated Guided Vehicles (AGVs) offer substantial benefits in efficiency, productivity, and safety, they also come with challenges that can impact success if overlooked. Recognizing and preparing for these potential obstacles allows organizations to mitigate risk, make informed decisions, and pave the way for a seamless, results-driven automation journey.
Common Risks in Automation Implementation
Every autonomous implementation, whether mobile robots or other advanced technologies, comes with inherent risks. Some of the most common pitfalls include:
Lack of Internal Alignment
One of the primary reasons automation projects falter is misalignment among key stakeholders. If operators, leadership, and other team members are not on the same page regarding goals, expectations, and execution, resistance can arise, leading to inefficiencies and setbacks. Successful implementations require clear communication and consensus-building across all levels of the organization.
Underestimating Change Management
Technology alone does not drive success—people do. Organizations often overlook the importance of change management, including proper training, communication, and workflow adaptation. Without these, employees may struggle to adapt, leading to lower adoption rates and inefficiencies, resulting in lower ROI or even a failed automation journey.
Choosing the Wrong Solution for the Problem
Selecting the right automation solution requires a thorough evaluation of operational needs. Companies must collaborate with experienced vendors to assess their workflows, facility constraints, and business objectives to ensure they choose the most appropriate application. Misaligned automation solutions can result in wasted investments and suboptimal performance.
Failing to Consider Scalability
Many organizations implement automation without considering future scalability. A solution that meets current needs but does not scale effectively can become a bottleneck as demands grow. Choosing scalable technologies ensures long-term efficiency and maximized returns on investment.
Risks Specific to Mobile Automation
When it comes to mobile automation, unique challenges must be addressed to ensure successful deployment and operation.
Poor Facility Layouts and Route Planning
Most existing facilities were not originally designed with automation in mind. Optimizing traffic flow where mobile automation shares space with manual vehicles and pedestrians requires careful planning. Common challenges include unclear right-of-way rules, inefficient intersection management, and poorly chosen pick-and-drop locations, which can limit efficiency and require frequent adjustments.
Ignoring Payload and Variability Considerations
Mobile automation must accommodate real-world variability, including diverse types of loads. Manufacturing environments often require vehicles to manage hundreds of unique payload types, which, if not considered, identified, and tested with the technology, can lead to disruptions in automated workflows.
Lack of Operational Buy-in
Operators may initially resist working alongside mobile automation, fearing job displacement or disruptions to their routines. Early negative experiences can further hinder adoption. However, gaining operational buy-in is critical. Engaging employees early, demonstrating the benefits of automation, and integrating mobile automation into daily workflows in a way that supports rather than replaces workers, fosters smoother adoption and improved ROI.
Inadequate Fleet Management Strategy
A robust fleet management system is essential for optimizing mobile automation operations. Without proper oversight, the vehicles can create traffic bottlenecks, reduce throughput, and operate inefficiently. Businesses must invest in real-time monitoring and analytics to manage and optimize their fleet effectively.
Lessons Learned from Implementing Mobile Automation
Successful implementations share common themes that businesses can learn from:
Define Clear Problem Statements
Facilities that clearly define their automation goals—whether reducing labor dependency, increasing throughput, or improving safety—experience higher success rates. A well-defined problem statement ensures focused implementation and measurable results.
“Start with a Win”
Rather than attempting to automate the most complex workflows first, businesses should start with applications that have a high probability of success. This builds confidence, generates quick wins, and paves the way for further automation expansions.
Engage Operators Early
The most successful implementations involve frontline employees before deployment begins. When operators understand and are trained on the technology, adoption improves, resistance decreases, and ROI accelerates.
Integration with Existing Workflows
Mobile automation should enhance, not disrupt existing workflows. Integrating the fleet with a facility’s Warehouse Management System (WMS), Enterprise Resource Planning (ERP) system, and other infrastructure ensures seamless operations.
Intentional Scaling
Businesses should scale automation efforts gradually and strategically. Starting with proven success, building confidence, and expanding purposefully ensures long-term success.
Mitigating Risks in Mobile Automation Implementation
Organizations can take proactive steps to mitigate risks and maximize the benefits of mobile automation:
Invest in Upfront Planning
Thoroughly assessing workflows, facility layouts, and operational needs before deployment sets the foundation for a successful implementation. Proper planning minimizes disruptions and ensures the chosen solution aligns with business goals.
Train and Educate Employees
Training is essential for smooth adoption. The more familiar leadership, operators, and employees are with mobile automation, the faster they can adapt to and benefit from automation.
Partner with Experienced Vendors
Working with a trusted automation partner ensures best practices are followed. A knowledgeable vendor can help guide successful implementations, provide ongoing support, and help address potential challenges quickly.
Final Thoughts: The Future of Mobile Automation
Mobile automation is not a one-time project but an ongoing strategy. Businesses that view these vehicles as part of an adaptive, evolving approach will gain the most long-term value.
While mobile automation offers flexibility, structured environments with clear traffic flows, standardized load placements, and well-coordinated operations enhance efficiency. Investing in mobile automation today sets businesses up for scalable, intelligent, and connected operations that offer a competitive advantage in an increasingly automated world.
By understanding and addressing the risks of mobile automation implementation, organizations can ensure a smoother transition, improved workforce engagement, and long-term success in their automation journey.
Source: Seegrid
To find out more about MHI’s MAG Industry Group: https://www.mhi.org/mag
For further articles/podcasts from MAG:
The Evolution of AGVs and AMRs
Common Misconceptions with Mobile Robotics
Cybersecurity and Your Robotics
Essential Sensors for Safe AMRs
Integrating Mobile Robots Into Your Operations
Building Sustainability Through Mobile Automation
Podcast: Energizing Mobile Automation
