Payback Under a Year: Realistic Assumptions and Levers

Automation vendors love to promise “payback under 12 months.” It’s achievable — but only when assumptions reflect real operations and optimization starts at the design phase.

1. Focus on Fast Wins

• Automate repetitive manual processes with short cycle times.
• Retrofit modular systems instead of full-line replacements.
• Leverage existing PLC and sensor infrastructure.

2. Levers That Cut Payback Time

ROI improves dramatically when:

• Energy waste is reduced by AI-driven control (up to 15%).
• Scrap falls through vision-based inspection.
• Unplanned downtime drops via predictive maintenance.

3. The Danger of Over-Promise

ROI that looks great in Excel often collapses under real OEE data. Build models with validated cycle times, not vendor marketing numbers.

Example

An SME achieved sub-12-month payback by automating just two manual packaging stations. The rest of the plant followed after measured success.

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• Total Cost of Ownership for Robots and AMRs

Conclusion

Realistic payback starts with disciplined assumptions. Track OEE, energy, and labor savings monthly — and prove ROI with real data, not estimates.