Home » Why the last 20% ruins your automation budget

The last 20% is where automation projects go off track

Full automation looks efficient - until complexity, IT and exceptions take over.

The problems with automation start when you chase 100%

The ambition to go all the way is often also the reason why it fails, as the last 20% introduce a level of complexity that real operations rarely can support.

This is where timelines slip, budget double and ROI disappears.

What hides inside the last 20%

Before you decide on a fully automated solution, ask yourself what it actually takes to automate everything.
The last 20% often looks small in a proposal but it carries most of the complexity.

ERP integration: Requires perfect data, strict processes and no deviations.
Rigid set-ups: Pallets, products and layouts must match the system — not reality.
System complexity: More integrations mean more failure points.
IT dependency: Changes, updates and errors require ongoing IT support.
Strong data discipline: Master data, naming conventions and processes must be flawless — every day.
Infrastructure demands: Stable Wi-Fi everywhere, all the time.

Real operations are not perfect - and never will be

Automation is often designed for ideal conditions.
Real operations are built on variation.

Everyday reality looks like this:

The more automation tries to control reality, the more fragile it becomes.

We automate what creates value - not what creates complexity

With LogiRobot, you automate repetitive and time-consuming pallet transport. It works from day one and frees up operators to focus on more complex, value-adding tasks.