The "Unpaid" Hours
The biggest advantage of a robot isn't speed—humans are often faster at loading a single part. The advantage is consistency and breaks.
- Human: 8 hour shift - Lunch - Breaks - Meetings = ~6.5 hours spindle time.
- Robot: 24 hour potential. No lunch. No bathroom breaks. No sick days.
| Cost Factor | Manual Operator | Robot Cell |
|---|---|---|
| Upfront Cost | $0 (Hiring) | $80,000 - $120,000 |
| Hourly Rate (Burdened) | $35/hr (Inc. Benefits) | $2/hr (Maintenance) |
| Annual Cost (1 Shift) | $72,800 | $28,000 (Amortized 5yr) |
| 5 Year Total | $364,000 | $140,000 |
The Hidden Benefit: Lights Out Machining
The calculation above assumes 1 shift. If you run a "ghost shift" (unattended overnight), the robot pays for itself in 6-9 months. Even running just 4 extra hours after everyone goes home increases shop capacity by 50% without hiring a night crew.
When NOT to Automate
Robots aren't magic. Don't automate if:
- High Mix / Low Vol: If you change setups every 5 parts, the robot programming time kills the efficiency.
- Deburring is Manual: If the operator is deburring/inspecting while the machine runs, that labor is already "free". A robot can't inspect (easily).