Why Change Can Be Challenging

In any business, but especially in manufacturing, change can feel like a risky, even unnecessary, disruption. With products to deliver and quotas to meet, it’s often easier to maintain the status quo rather than consider new investments in technology or process improvements. Here’s a closer look at why manufacturers may find it challenging to invest in new processes and technologies, despite the potential long-term benefits.

Inertia: The Comfort of Familiar Processes

One of the primary barriers to implementing new technology is inertia—people are used to doing things in familiar ways. When a particular process has been followed for years, it becomes ingrained, and even the thought of changing it can be daunting. Familiar processes, tools, and methods often feel “safe” because everyone knows how they work, and there’s no immediate pressure to shake things up. 

In manufacturing, where consistency is key to quality, change is often seen as a potential source of error or delay. This reluctance to move away from established practices creates a sense of inertia that can be hard to overcome, even if new solutions promise greater efficiency and productivity.

Unique Process Quirks: No Two Factories Are the Same

Each manufacturing operation is different, with unique needs based on what it produces, the layout of the factory, and the personnel involved. This creates specific process quirks that make it feel like only custom, complex solutions could work. 

For example, a factory making delicate electronics may have specific handling requirements that make standard automation solutions seem unsuitable, while another producing large items may have space constraints that limit the practical options for equipment placement. This feeling of being “too unique” to benefit from general solutions reinforces inertia and fosters the belief that current processes can’t easily be improved or standardized.

The Challenge of Calculating ROI: Lack of Good Data

Another major hurdle for manufacturers is accurately calculating the return on investment (ROI) of new technology or process changes. Reliable ROI calculations require solid baseline data on current performance metrics—cycle time, scrap rates, labor hours, and more. But many operations do not collect or analyze this kind of granular data, focusing instead on immediate production goals.

Without a clear picture of current inefficiencies or the potential gains from a new investment, decision-makers are left in the dark. This uncertainty can make investing in new technology feel like a gamble rather than a calculated decision. For many, it’s easier to avoid the risk and stick with existing processes rather than invest in technology that might not provide clear, measurable returns.

Life Goes On: The Status Quo Mindset

Manufacturing environments are driven by the need to meet production schedules, maintain quality standards, and minimize downtime. Given these pressures, a “life goes on” mentality often develops, where the focus is on maintaining daily operations rather than exploring disruptive changes. Teams are busy, resources are stretched, and disrupting workflows to implement new technology can feel like a luxury rather than a necessity.

There’s also a sense that if current processes are “good enough,” there’s little incentive to push for improvement. The attitude is often, “We’ve managed fine with what we have; why change it?” This mindset can prevent forward momentum, locking companies into routines that may meet today’s needs but leave little room for future growth or efficiency.

Overcoming the Resistance to Change

While the barriers to investing in new processes and technology are real, they aren’t insurmountable. Overcoming these challenges requires a strategic approach.

• Incremental Change: Start with small, manageable improvements that can deliver immediate benefits. This can build confidence in new technologies and demonstrate value without overwhelming teams.
• Flexible Solutions: Work with technology providers who can tailor solutions to your unique processes. Many modern technologies offer modular options that allow companies to adopt only what fits their specific needs, minimizing disruption.
• Data Collection: Begin tracking basic performance metrics if you aren’t already. Having a baseline can help identify improvement areas and make ROI calculations more accurate and achievable.
• Education and Training: Helping teams understand the benefits of new technology and providing training can ease resistance. When employees see the value, they’re more likely to embrace change.

Final Thoughts

The road to adopting new processes and technologies is paved with challenges, from the inertia of familiar practices to the complexities of unique processes and the difficulty of calculating ROI. However, a strategic approach that emphasizes incremental change, tailored solutions, and clear communication can help overcome these obstacles. Embracing new technology may seem daunting, but the benefits—greater efficiency, reduced costs, and enhanced competitive edge—are often worth the effort.