Having worked in the metals manufacturing sector for years, I see the same conversations happening again and again at industry events. Everyone knows we need to automate manufacturing processes, but the barriers feel overwhelming. At Metals Expo recently, I was asked about what's really holding back UK metals manufacturers – and I think it comes down to three main issues.
Barrier one: the ROI challenge in manufacturing automation
Return on investment is absolutely everything with every decision we make in metals manufacturing. The problem is, it's incredibly hard to determine exactly what the right approach is when you're looking at industrial automation solutions. There are so many different ways to solve the same problem, and the information out there is complex and sometimes contradictory.
My solution: start with targeted automation
Don't try and do too much too soon and automate manufacturing processes all at once. Pick one process that's causing you the most grief – whether that's quality issues, bottlenecks, or safety concerns – and focus your automation ROI calculation on that. You'll get clearer numbers and a better understanding of what works before you scale up.
Barrier two: legacy systems integration challenges
We've got amazing mechanical machines that are 20-30 years old in this industry, and they still do exactly what they did when they were installed. They're incredible pieces of equipment. The problem comes when you need to integrate legacy manufacturing systems sympathetically. The goal is to gain production data, feedback and modern machine capabilities without the cost and disruption of ripping everything out.
My solution: think integration, not replacement
Work with automation suppliers who understand legacy systems integration and can build bridges between old and new technology. It might not be the prettiest solution, but it's often the most practical and cost-effective for UK manufacturing companies. And be patient – this kind of integration takes time and innovation to get right.
Barrier three: manufacturing skills shortage crisis
This is the one that really worries me. We're struggling for people and skills in metals manufacturing. We've lost so much of our manufacturing knowledge base over the last couple of decades. We can't find people to get the most out of the equipment we've got, and we struggle to find people who can help navigate these complex automation implementation issues – how to identify bottlenecks, how to improve reliability.
My solution: invest in knowledge transfer now
Document everything now, before it's too late. Get your experienced engineers to mentor younger staff and capture their knowledge. Partner with local colleges and training providers to develop the manufacturing skills you need. Don't try to find unicorn candidates who know everything – it's often better to train someone with the right attitude than wait for the perfect CV.
The bigger picture: overcoming automation barriers
These three barriers – ROI complexity, legacy system integration, and skills shortages – feed into each other. But they're not insurmountable for UK metals manufacturers. The key is to stop thinking about manufacturing automation as one massive project and start seeing it as an ongoing journey of improvement.
The companies that are succeeding aren't necessarily the ones with the biggest budgets or the newest kit. They're the ones taking a practical, step-by-step approach to industrial automation and investing in their people alongside their technology.
They’re also the ones that recognise and value the skills and knowledge within their workforce. Automation can be used to reduce the dull, dirty, repetitive tasks – freeing up those with knowledge and insight to be able to have more input into the business.
Taking action on manufacturing automation
We can't afford to stand still whilst our competitors move forward with automation technologies. But we also can't afford to rush into expensive mistakes. The answer is somewhere in the middle – thoughtful, incremental progress that builds on what we've already got.
Ready to discuss your automation challenges? At Transicon, we understand the unique pressures facing UK metals manufacturers. Contact our team to explore practical automation solutions tailored to your specific needs.
About the author: Jen Hughes is general manager at Transicon, bringing extensive experience in metals manufacturing and automation implementation. She regularly speaks at industry events including Metals Expo on manufacturing technology trends.
