Fail to Plan, Plan to Fail: How Good Automation Goes Bad

It’s all too common in modern manufacturing: A packaging line is installed, expectations are high … and then things don’t go quite as planned. Downtime creeps in. Deadlines are missed. The automation brought in to improve production efficiencies is suddenly an obstacle.

In this type of scenario, blame usually rests on “faulty” equipment. More often than not, however, automation failures aren’t about the machines; they stem from poor planning that happens well before machinery ever arrives on site.

That’s not to say people don’t care. Rather, automation is complex. In the rush to find a solution that corrects shortcomings and helps achieve operational goals, cutting corners during the planning stage is common. Skipping what appear to be “optional” steps can ultimately cost time and money — the two things you’re turning to automation to help save.

Let’s take a real-world look at what causes some automation projects to go sideways, and the planning stage fixes you may need to implement to avoid trouble.

What “Skipping Planning” Actually Looks Like

Skipping planning isn’t strictly about omitting certain steps in the interest of time. Making decisions based on ill-defined objectives can be equally as damaging, such as:

• Creating vague project goals (“make everything faster”)
• Overestimating equipment performance expectations (“one machine can do it all — perfectly”)
• Presupposing your product will work on any machine, without adequate testing or film validation
• Ignoring the impact of upstream/downstream equipment on the performance of new automation
• Misunderstanding roles and responsibilities during system installation and integration

At first glance, these general parameters may suggest a certain flexibility in your approach to adopting automation solutions. In reality, remaining this broad brings with it substantial productivity, operational, and quality risks. 

The Risks of Poor Planning

“Planning feels like a delay, but really it’s what prevents delays later.”
- Jordan Miller, GM of Customer Care

There’s a boomerang effect to cutting planning steps that ripples throughout a company: 

Lost Productivity

• Delayed commissioning and start-up. Without detailed project scoping, layout planning, and scheduling, equipment may not arrive or install on time — which translates to expensive downtime, idle lines, and potential missed product rollouts and expansions
• Upstream/downstream process misalignment. Improper planning may result in packaging that doesn’t integrate smoothly with the design or speed of other production line machinery (conveyors, fillers, labelers, etc.) causing bottlenecks that reduce overall operational efficiency (OEE)
• Frequent changeovers and resulting downtime. Poorly specified systems may be able to run multiple products, but at the cost of frequent, longer, and more complex changeovers as compared to equipment custom-engineered to address core needs

Limited Operational Strategies

• Inflexibility to future needs. Shortsighted planning could leave you with systems that can’t be easily modified or scaled, meaning reduced ability to pivot toward evolving product lines, market shifts, etc
• Hidden costs. If unanticipated requirements show up post-planning (e.g., needing additional floor space, different power requirements, etc., for the system), correction can inflate the total cost of ownership (TCO) and reduce ROI
• Safety concerns. Not fully vetting system ergonomics, maintenance access, or other safety features in terms of need could lead to unanticipated worker injury, or if they aren’t up to code with state law there could be fines imposed

Poor Quality

• Lack of packaging integrity. If materials handling, package sealing, and filling specs aren’t considered during planning, defects such as underfilling, contamination, or leaks might occur
• Regulatory non-compliance. If the packaging system isn’t aligned with regulatory or brand requirements throughout production (e.g., date codes, lot tracking, nutritional info), it may result in mislabeling, violations, fines, and potential danger to the public depending on the product
• Costly waste and rework. Improper planning could contribute to significant waste of packaging materials and product due to unidentified issues such as film registration and tracking errors, or incompatible packaging material specs

The Power of Partnerships

There’s no need to cut corners or take risks when it comes to your automation strategy when you shop for partnerships with the same diligence as you do equipment. Collaborating with an equipment manufacturer that takes the time to ask the right questions — and truly listen to the answers — promotes solutions-focused thinking from day one.

“One of the things that makes Viking Masek unique is that we can provide a system front-to-back. Other suppliers have a niche, which leads to holes in product offerings and their ability to support complex systems.

We commit to understanding our customers’ priorities and focus, and to asking the questions that will provide what we need to build their equipment. Everything is tailored to align with their focus, needs, and process.”

Our customer-first philosophy translates to real-world success stories, including:

• Taking a major pizza brand from struggling to package bulk toppings at 45 BPM  to an astounding 72 BPM by designing and installing a M250 packaging machine. The new average of 280-285 cases/hour enabled consistent full-shift performance and helped our customer meet all productivity targets
• Helping a family-owned commercial bakery implement a turnkey, fully integrated system featuring two VFFS Velocity high-speed, single-serve pouching machines that doubled their production output while reducing on-line labor by 40%. Their VP of manufacturing weighed in: “Viking Masek helped us tremendously as a single source provider for the entire line. The fact that I worked with them in the past and wanted to work with them again demonstrates how much I value their expertise!”
• Collaborating with a fast-growing pet treat manufacturer to replace aging automation to overcome scaling concerns and labor-heavy manual packaging processes. Significant equipment planning, testing and trail runs pointed to a two-phase install. Adding an 8S-235 premade pouch machine and a Synchropack-60 Flow wrapper led to 70 different products running 24/7 and a 300% increase in pack rate — 40 BPM v. 10 manual BPM

Plan on It!

The most successful automation outcomes don’t happen by chance. They’re built on clear goals, open collaboration, and trusted partnerships. If you're thinking about how to avoid the planning pitfalls we've covered here — or have something completely different on your mind — it may be time to start a conversation. Contact our team of experts.  Viking Masek is here to listen, ask the right questions, and help you move forward.