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Manufacturers Spend Millions Correcting Avoidable Errors When Upgrading Sites

UK manufacturers spend on average over £2.5m on correcting errors when building a new or upgrading an existing manufacturing site that should have been spotted at the design phase. Nearly all (97%) of decision makers said that their organisation had made at least one mistake when implementing robotics or automation, according to new research commissioned by Visual Components.

The study revealed that mistakes and/or associated downtime in the manufacturing process typically costs organisations £98,000 on average, with 2% of respondents saying they incur costs over £1 million. With the cost of failure so significant, the acknowledgement that 59% of mistakes or faults could have been avoided with the use of simulation software shows the technology’s potential in helping organisations save significant sums of money.

The importance of simulation software in providing visibility to manufacturers is further supported by the fact that 30% of respondents noted that errors in implementing robotics or automation were due to focusing on the wrong area or process, leaving the problem unsolved.

Steve Morris, Country Manager UK & I at Visual Components said, “Our study results show that with an average of £2.5m spent on correcting errors in the building of new or upgrading manufacturing sites, organisations need to adopt simulation software to better visualise a project during the design phase and ensure costly mistakes don’t occur.”

These costly errors arrive at a time when the sector is already facing external cost pressures, with 17% of organisations citing Brexit, Covid-19 or the inability to secure funding as the primary challenge to upgrading an existing manufacturing site. Almost a fifth of respondents (19%) identified cost management as an important technology in the building or redesigning of the factories of the future.

About Visual Components

Visual Components is a developer of 3D manufacturing simulation software and solutions. Founded in 1999 by a team of simulation experts, it’s goal was to make manufacturing design and simulation technology easy to use and accessible to manufacturing organisations of all sizes. Today, Visual Components is recognised as a global leader in the manufacturing simulation industry and trusted technology partner to many leading brands. It offers machine builders, system integrators, and manufacturers a simple, quick, and cost-effective solution to design and simulate production lines. With solutions for manufacturing design, sales, and application development, it is trusted by hundreds of organisations worldwide to support critical planning and decision making processes.