Automation in high-mix, low-volume manufacturing is full of contradiction. It promises scale, speed, and consistency. But it also demands time, capital, and clarity. Automating the wrong thing creates waste. Doing everything manually creates drag. The advantage lies in figuring out where automation improvess the work.
At Amtech, automation is treated as a flexible tool. The strategy isn’t about doing more faster—it’s about improving what matters most. That starts with knowing when to build it and when to let go.
Automation Can’t Be Assumed
Not every process benefits from automation. Even high-volume operations have had to scale it back when it creates more problems than it solves. Elon Musk’s early push to automate production at Tesla is one example, where overengineering led to delays and costly adjustments.
In HMLV environments, the risks are higher. You don’t have predictable volume or long runs to justify highly specialized systems. Each build brings its own variables. Instead of trying to automate everything, the smarter move is to identify where the greatest value lives and focus there.
Optimize What You Can, Accept What You Can’t
Some tasks don’t scale, even when the tech is available. One example: selective soldering seemed like a good fit until the board layout required so much manual touch-up afterward that it canceled out the benefit. In that case, reverting to hand soldering made more sense.
That kind of situational awareness helps focus automation efforts where they’ll actually pay off. Tools like jigs, simple fixtures, and 3D-printed components can speed up low-volume processes without locking you into rigid systems. These kinds of solutions increase consistency and reduce operator fatigue without requiring long-term investments or elaborate engineering.
The point is to make the work easier, not more complicated.
Look for Signals, Not Absolutes
There’s no definitive list of what should or shouldn’t be automated. But certain patterns emerge. Repeated errors, excessive rework, or long setup times are all signs that a process might benefit from simplification or automation.
Start with a mindset that everything might be automatable. Then work backward from the need. In some cases, a quick fixture solves the problem. In others, the manual process is simply more efficient. Let real-world performance guide the decision. “You have to default that there is a way to automate it,” says Amtech CEO Jay Patel, “and then work backwards and say, actually, no, this doesn’t make sense.”
AI and Inspection as a Breakthrough
Inspection has historically been a difficult step to automate, especially when precision and variation collide. That’s changing quickly. Vision systems trained through machine learning are now catching defects, identifying process drift, and doing both in real time.
This shift has created major gains in yield and consistency. Automating inspection doesn’t remove people from the equation—it supports them by providing immediate feedback and highlighting issues before they become problems.
This is where automation works best: clarifying what matters and helping the team stay focused on value, not firefighting.
Choose Your Entry Point Wisely
Automation is more effective when it begins with the right problem. The 80/20 rule applies: target the 20% of activities creating most of the waste or delay. Whether it’s a recurring defect, a time-consuming handoff, or an inefficient workstation setup, begin where the pain is most visible.
Solve one thing well, then build on the results. Momentum comes from clear wins, not broad ambition.
Investing Without Getting Distracted
Technology doesn’t stop moving. What works well today may be outdated in a few years. But that doesn’t mean every new tool deserves your attention.
Treat automation like any other capital investment. Evaluate whether it improves capability, reduces waste, or makes your process more resilient. If it doesn’t, wait. The goal is to stay current without becoming reactive.
Ask Better Questions
Automation only delivers when it’s rooted in a deeper understanding of the process. Ask where the breakdowns are. Look at where your team spends the most time. Watch for signs of frustration, bottlenecks, or avoidable rework.
Those are the opportunities. The more clearly you see them, the more confidently you can act.