As someone invested in manufacturing, whether a company lead or floor technician, you’ll hear this phrase repeatedly: “Automation is the future.” And there’s data to support this claim. A 2023 study from the International Federation of Robotics shows the rate of robots being installed per human in manufacturing globally is rising at unprecedented rates as shown in Figure 1. Figure 1 Source: Global Robot Density in Factories Doubled in Seven Years - International Federation of Robotics The experts also agree. Economists like AMT’s Chris Chidzik have uncovered through an analysis across the U.S. Bureau of Labor Statistics a revealing trend: more manufacturers are moving toward automation to help alleviate labor shortfalls and increase labor productivity. Figure 2 Source: Productivity Path: How Increases in Automation Support Manufacturing Productivity But as a traditional small- to-medium-sized manufacturer with parts to make and employees to pay, the question becomes: why should I change what works? In today's rapidly evolving manufacturing landscape, adopting automation isn't just about technology — it must start with building a culture that fosters and sustains innovation over time. Companies that embrace continuous, incremental improvement and workforce development are best positioned to deploy and scale automation successfully. Only after this critical step can companies gain the competitive advantages of enhanced output and efficiency. Throughout this story, we use C&S Machine, a contract manufacturer in Niles, Michigan, specializing in high-precision parts for the aerospace and medical sectors, as a case study to show how this cultural shift works, and how it pays off in the real world. Automation Evolution, Not Revolution According to the Kaizen Institute, small, incremental changes in business operations over time drive sustainable growth and efficiency. Harvard Business Review reinforces this idea, emphasizing that companies must create an environment where employees at all levels are encouraged to identify inefficiencies and suggest solutions. Many manufacturers hesitate to adopt automation due to the misconception that it’s a massive, disruptive overhaul of their moneymaking apparatus. However, successful companies recognize that automation should be a steady evolution, not an all-at-once transformation. Incremental changes — starting small, refining processes, and expanding capabilities — enable businesses to build and sustain key momentum. C&S’s Strategic Implementation Under the leadership of CEO Dominick (Dom) Saratore, C&S Machine integrates automation strategically to elevate its humans, not eliminate them. Operators at C&S manage multiple automated cells instead of being tied to a single machine, transitioning their work from repetitive tasks to process optimization. This shift increases productivity, reduces errors, and enhances their employees’ stake in the game. C&S Machine, seeing how automation isn’t just a technology investment, prioritizes this cultural shift. Its employees help refine processes, monitor performance data, and optimize automated systems. Their employees’ engagement fosters innovation, ensuring automation efforts remain dynamic and adaptable. For example, when an aerospace customer required a family of precision parts to be made, C&S’s employees began by deploying just two specialized automation cells: A Makino EDM machine paired with a FANUC robot A Hardinge lathe with a FANUC LR-Mate loader robot and an integrated part probing system for dynamic compensation The results: 98% uptime (compared to 80% for manually loaded machines) and a scrap rate cut from 3-5% to less than 1%. These improvements were achieved through measured and adjusted improvements to employees and systems, not a complete overhaul. Employee Empowerment Automation investment without upskilling employees is a recipe for stagnation. Successful cultural shifts integrate creative workforce development programs so teams can fully leverage new technologies. Virtual reality (VR) training may be a powerful tool for this development, allowing operators to practice complex tasks in a risk-free environment before applying them. As highlighted in AMT’s article From Sports to Manufacturing: VR Training Changes the Game, immersive simulations accelerated the learning curves of Washington Commander quarterback Jayden Daniels. Through VR training, Daniels obtained the most NFL “Rookie of the Week” awards ever, the most offensive yards by a rookie, and the most touchdown passes in the final 30 seconds of regulation or overtime. The NFL proved the immense promise for manufacturers who follow in football’s footsteps when it comes to simulated training. Capable Specialists at C&S Returning to C&S Machine, the company embraces this training philosophy by investing in their machinists to become automation specialists, ensuring technology adoption enhances workforce capabilities, rather than displacing valuable employees. We would expect C&S Machine to bring VR simulation training into their shop in the future, but only when the time is right for their employees and culture. Data-Driven Decisions & External Experts A successful automation strategy relies on good data. From asynchronous to real-time data input, an intentional data collection is fundamental to successful automation, enabling: Continuous monitoring of system performance Predictive maintenance to reduce downtime Refinement of automation processes based on real-world insights. But not one factory is on an island. Manufacturers can and should start the shift toward innovation by first engaging with experts, industry events, and professional organizations, such as: Automation Consultants: Experts guide implementation and ensure the right technologies are deployed at the right scale and time. Trade Shows & Networks: Events like the International Manufacturing Technology Show (IMTS) and associations like ARM (Advanced Robotics for Manufacturing Institute) provide insights into emerging trends and best practices. Collaborative Partnerships A final insight from C&S Machine: build strategic, agile partnerships. Unlike companies that rely on fixed automation vendors, C&S Machine selects implementation partners based on project-specific expertise, reducing risk and ensuring effective integration while remaining open to the newest ideas. The Roadmap to Scalable Automation Automation is not just about robots and software — it is about creating a culture of continuous improvement where technology and workforce development go hand in hand. Manufacturers can scale automation effectively while ensuring long-term success by starting small, refining processes, leveraging external expertise, and investing in employees. C&S Machine’s success story demonstrates that, when automation is implemented thoughtfully, companies can achieve higher uptime, lower scrap rates, and an empowered workforce — proving that the future of manufacturing belongs to those who embrace innovation as an ongoing journey, not a one-time investment. Keep the Momentum Going Curious how to turn a culture of continuous improvement into tangible results? Should I Consider a Cobot or a Robot?” Visit IMTS.com/automation for expert resources and insights. Attend the ARM Insitute’s 2025 Annual Member Meeting where I will present, "A Journey of Automation from Late Adaptor to Innovator.”
Discover how manufacturers can build momentum for tech adoption by encouraging fresh thinking, upskilling teams, and refining operations for long-term gains.
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