MAKING AUTOMATION MORE AFFORDABLE: REFRAMING THE COST OF ROBOTICS

Automation and robotics have the potential to solve many of the challenges facing manufacturers today, from rising labour costs and staff shortages to the need for higher production efficiency and build resilience. But although the case for investment in industrial automation is strong, in the current climate of corporate belt-tightening, many automation projects do not make it off the drawing board because of the perceived high upfront investment. In this article, Oliver Selby, head of sales at FANUC UK, looks to reframe the cost of robotics and demonstrate its affordability.

Increasingly, capital decisions are evaluated in terms of ‘freeze, flee or build’: pausing or deferring a decision until key assumptions stabilise (freeze); redirecting capital away from an area of exposure (flee); or accelerating an investment to capture an opportunity or establish a competitive advantage (build). All too often, automation projects get ‘frozen’, not because the rationale is flawed but because they are deemed unaffordable or non-urgent at a time when cash is in short supply. However, choosing this option can lead to considerable inefficiencies and strategic disadvantages, putting manufacturing businesses in a vulnerable position.

Therefore, when constructing a justification for investing in automation, it is important to demonstrate why the project should be treated as a priority, and how it will be financed. By moving the focus from well-trodden arguments to reframing the economics of robotics – and showing why the cost of waiting is usually higher than the cost of taking a decision now – project managers can make the case for immediate investment irrefutable.

Here are six points that manufacturers can draw on to build an automation investment proposal that stacks up.

First and foremost, robots are today more affordable than ever before.The cumulative UK inflation rate over the past 20 years (2006-2026) is approximately 70-80%, based on Consumer Prices Index (CPI) data. Yet over this same timeframe, the average purchase price of an industrial robot has only increased 20%. Investing in equipment that has registered price growth lower than the general rate of inflation can be a strategic move, as it effectively makes it cheaper in real terms. If robot prices are rising by 1% while the overall inflation rate is 3%, manufacturers are purchasing a productive asset that is decreasing in relative cost compared with other investments.

The second point is the emergence of multiple finance options that open up access to robotics. Historically, most automation projects were funded via high street bank loans. Today, there are many finance routes, some of which offer far more flexibility.

Recent years have seen some robotics integrators partner with finance providers to offer flexible funding options, such as staged payments and asset finance, helping manufacturers invest in technology without heavy upfront costs. Asset-based lending has also become more common as a flexible alternative to traditional high-cost bank loans, allowing businesses to acquire new equipment or technology by using assets such as receivables or inventory as collateral. FANUC would advise any company embarking on an automation project to speak to their integration partner or OEM supplier about available finance.

Third on the list is assurance schemes, which build trust for lenders. Trust in robotic systems is growing, driven by a maturing assurance ecosystem, and this confidence is starting to filter through to lenders. Earlier in 2026, Automate UK launched the UK’s ‘Robot Integrator Standard’ in association with BARA (British Automation and Robot Association). Designed to ensure that integrators follow best practice, the standard provides assurance of safe, high quality, and reliable robotic and vision solutions, thereby reducing the risk associated with automation projects.

FANUC UK has also built up its own network of trusted authorised system integrators; partners selected for their ability to provide specialised, low-risk automation. It is expected that such schemes will translate into more favourable financing arrangements for borrowers through reduced risk for lenders.

A fourth point worthy of consideration is the transfer of costs from CapEx to OpEx. While robotics investments are traditionally structured as CapEx – a large outright purchase of a piece of equipment – over time, service has become an increasingly critical element of these projects.

As automation technology has advanced, service has gone from being a post-installation afterthought to a fundamental pillar of success. Most installations today incorporate simulation, training (of both AI systems and human operators), and ongoing servicing and support. From a financial perspective, this workflow has created an opportunity to move some project costs from CapEx to OpEx, converting them into ongoing, manageable and flexible expenses. Taking this strategic decision can help make automation more affordable by reducing the upfront investment, preserving cash flow and enable the apportioning of costs to different cost centres.

Point number five: robots are becoming maintenance-free. Traditionally thinking accepts that annual maintenance costs for an industrial robot will run to 3-10% of the original purchase price. This estimate is dependent on the size of the robot, with maintenance costs for larger robots typically coming in at the lower end of the range. Finance providers have accounted for these costs by bundling them into monthly payments. However, technological advancements such as predictive maintenance, accelerated life testing and grease-less components are moving robots into a new ‘maintenance-free’ paradigm.

Among robot manufacturers, FANUC is leading the way here, with its reliability and eight-year maintenance-free promise. This pledge is making robots more affordable over their lifetime. Such savings will soon be reflected in the structure of finance deals, as robots can be guaranteed to run maintenance-free for the duration of the financial agreement.

Last but not least, automation helps reduce manufacturing overheads.The argument that investing in automation allows businesses to produce more with less has never been stronger. Industry is entering an era of precision manufacturing with technologies such as robotics, AI and sensors enabling real-time monitoring and optimisation of production parameters, quality metrics, material usage and energy consumption. The net result is that manufacturing has the potential to be leaner, more productive and more resource-efficient than ever before.

These advancements are strengthening the economic case for automation. For example, FANUC systems feature AI-driven diagnostics, power regeneration and IIoT solutions that enable intelligent energy recovery, reduce waste and improve uptime.

With 2025-2006 the most expensive period on record for UK businesses, a growing number of manufacturers are turning to automation as a strategy for futureproofing against inflation and maintaining a competitive edge. Reduced risk for lenders is translating to more favourable packages from finance providers. Technological advancements are continuously improving robot productivity, reliability and resource utilisation to drive a structural decline in cost per unit of output. Moreover, in real terms, robots are getting cheaper. For manufacturers, these factors make automation an increasingly powerful lever for expanding margins and scaling production efficiently and flexibly.

More information www.fanuc.eu

Steel Manufacturer Cuts Costs 50% With Bespoke Solution

Yorkshire-based company Shafton Steel Services has significantly reduced both costs and maintenance time after replacing a traditional conveyor system with a tailored lifting solution. At its facility in South Yorkshire, Shafton Steel Services, part of Billington Holdings’ group of companies, operates a robotic coping and drilling line that generates large quantities of steel scrap, which falls into a pit beneath the machine.

Typically, conveyor systems are used to handle this type of waste. However, due to space constraints at the installation site, the company opted for an alternative solution based on a scissor lift table. A conventional conveyor system would have required too large a footprint to accommodate the machine in its intended location.

Compared to a conveyor system, the footprint is significantly smaller, while maintenance requirements and safety risks are reduced. The lift table allows us to raise the entire unit by crane, ensuring full access to all components and safer cleaning of the pit.

“It’s 20-25% easier to perform maintenance work on the lift compared with a conveyor, which has a clear impact on our bottom line,” says Ryan O’Connor, profile manager at Shafton Steel Services.

The company commissioned the design and implementation of the scissor lift table, which runs on a rail system inside the pit. Steel scrap is collected in a bin placed on the lift platform and transported to one end of the system, where it is raised to floor level and removed. The total investment came to just under £29,000, approximately half the cost of a comparable conveyor system, according to O’Connor.

The lift table was developed and supplied by Sax Lift. The project reflects a broader trend for the company, which is seeing increasing demand for bespoke products in the UK market.

More information www.saxlift.com

Humanoid Robots Show ROI But Success Is Output Dependent

Humanoid robots are moving from prototype validation toward early commercial deployment, with automotive manufacturing and logistics expected to form the core demand base over the next decade. According to IDTechEx, the humanoid robot market across sectors like automotive and logistics is forecast to grow rapidly over the coming years, reaching approximately US$25bn by the early 2030s. Annual shipments are projected to approach 1.8 million units by 2036, driven primarily by automotive manufacturing.

Return on investment (ROI) is clearly key, with IDTechEx calculations suggesting that humanoid robots are beginning to show a clear payback pathway under favourable deployment conditions. By 2026, payback periods can be reduced to around 6 months under high-utilisation scenarios, compared with approximately 15 months under medium utilisation.

As hardware prices continue to decline and deployment experience improves, ROI feasibility is expected to strengthen across a broader range of industrial applications. However, a shorter payback period should not be interpreted as guaranteed profitability. The core variable in humanoid robot economics is not only equipment cost, but the effective value of the work delivered by the robot. In practical terms, this means whether the robot can perform economically valuable tasks consistently, reliably and at a sufficient level of productivity across different environments.

This remains the main bottleneck for large-scale adoption. Humanoid robots are becoming increasingly feasible in selected structured industrial environments, but capability limitations remain clear in complex, variable or safety-critical tasks.

Overall, IDTechEx believes that the cost advantage of humanoid robots is becoming increasingly visible, and ROI can already be demonstrated in selected deployment scenarios. However, large-scale commercialisation will depend on continued improvements in software capability, task generalisation, system integration and deployment efficiency, rather than hardware cost decline alone.

More information www.IDTechEx.com/HumanoidRobotics

Bringing Connected CNC Automation To IMTS 2026 Exhibition

North American manufacturers are under growing pressure to increase productivity, use skilled labour more effectively and respond to changing production demands. At IMTS 2026, CNC automation specialist Tezmaksan will demonstrate its CubeBOX range of robotic machine tending systems. The Turkish engineering and automation company will show how CNC machine tending can be made more accessible, flexible and practical.

Tezmaksan will exhibit with its North American partner, Dynamic Machine, at McCormick Place in Chicago from September 14 to 19, 2026. Dynamic Machine supplies CNC machine tools, automation and turnkey manufacturing systems across North America. At Booth #339430, the company will present variations of CubeBOX, a modular automation cell that combines robotic machine tending, part storage, pallet handling and control software to suit different production requirements.

“North American manufacturers are looking for practical ways to increase capacity, manage labour pressures and adapt to changing customer requirements,” explains Hakan Aydoğdu, CEO of Tezmaksan. “Our message at IMTS is that automation does not need to begin with a large or complicated project. The CubeBOX range gives manufacturers different entry points depending on their machines, applications, production volumes and available floor space.”

The systems on the stand will demonstrate different approaches to automated production.

CubeBOX Blues DR-3P, for example, uses a drawer-based configuration to organise and present components for robotic loading, while CubeBOX Blues RT-Vice deploys multiple vices arranged around a rotary table. The CubeBOX pallet pool supports automated pallet handling, with EcoLEAN V1 providing a compact collaborative robotics option.

“The products tell a connected story,” continues Aydoğdu. “Whether a manufacturer needs drawer-based part handling, vice automation, pallet movement or a collaborative solution, the objective is the same: to reduce unnecessary manual handling, keep machines productive and make production easier to manage.”

More information www.tezmaksanrobotics.com

Regulation Shifts Safety Responsibilities To Machine Operators

Leuze is advising manufacturers, machine builders and operators to prepare early for the implementation of the Machinery Regulation (EU) 2023/1230, which will apply from 20 January 2027.

While manufacturers remain responsible for compliance when machinery is first placed on the market, the new regulation expands responsibilities for operators throughout the machine’s operational lifecycle. It introduces requirements covering cybersecurity, artificial intelligence and substantial modifications, with operators making significant changes potentially assuming the role of manufacturer. This can require risk assessments, technical documentation and conformity assessments before modified machinery is returned to service.

With official implementation guidance still developing, many organisations face uncertainty over how the regulation will apply to existing machinery. Leuze therefore recommends that manufacturers and operators begin reviewing their machinery, documentation and modification procedures now.

“As companies prepare for the transition, understanding how the new regulation applies to existing machinery is becoming increasingly important,” says Markus Erdorf, senior safety consultant at Leuze. “Organisations should begin reviewing their machinery, documentation, cybersecurity strategies and modification procedures rather than waiting for the implementation deadline.”

A notable development is the integration of cybersecurity into machinery safety requirements. Organisations will need to protect machinery against unauthorised access, data manipulation and other cyber risks, supported by appropriate risk assessments and documentation. This requires closer collaboration between safety engineers, automation specialists and IT security teams.

Leuze recommends early review of regulatory requirements, close co-operation with machinery manufacturers and system integrators, thorough documentation of safety-related modifications and inspections, and assessment of whether planned changes constitute substantial modifications.

“The responsibility for machine safety no longer ends when equipment is commissioned,” adds Erdorf. “Preparing today will help reduce compliance risks and ensure safe machine operation throughout its lifecycle.”

More information www.leuze.com