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The 7 Most Common Myths About Industrial Automation (And the Truth Behind Them)
Industrial automation is everywhere—from food processing lines to high-tech automotive plants. Yet despite its proven value, many misconceptions still keep decision-makers second-guessing when and how to embrace it. Use this guide to bust the most common myths and replace them with truths you can use to plan smarter, prevent downtime, and get more from your plant investments.
Myth 1: Automation Replaces People
Headlines often warn that automation will wipe out jobs. In practice, automation takes over repetitive, hazardous, or error-prone tasks so people can focus on higher-value work—troubleshooting, optimization, and supervision. Most manufacturers now view automation as a way to empower their workforce, not eliminate it.
- 66% of finance leaders believe automation augments rather than replaces jobs. IoT Analytics
- U.S. manufacturers are increasingly turning to automation to complement workers and accelerate recovery post-COVID. TIME (Schneider Electric)
Myth 2: Automation Is Too Expensive for Mid-Sized Plants
It’s easy to assume automation is reserved for billion-dollar companies. Today’s solutions are modular, scalable, and cost-effective. From smarter HMIs to targeted drive upgrades, bite-size steps can deliver fast ROI when aligned to real bottlenecks.
- The industrial automation market is projected to reach $226.8B by 2025 with a ~10.8% CAGR. MarketsandMarkets
- A Forrester TEI study of Plex (Rockwell Automation) found 412% ROI over three years and payback in <6 months. Forrester / Plex
Myth 3: Legacy Equipment Can’t Be Integrated with New Systems
Many plants hesitate to upgrade believing legacy equipment must be scrapped. In reality, protocol converters, adapter modules, and IIoT gateways let old and new coexist. Hybrid strategies extend asset life while you modernize at your pace.
- A medical device manufacturer boosted throughput by 23% by digitizing legacy assembly equipment with minimal new investment. IndustryWeek
- 18.8B IoT devices expected in 2024 (up from 16.6B in 2023), underscoring massive integration across legacy and modern systems. IoT Analytics
IAC connection: At Industrial Automation Co. we source both current-gen and legacy parts—Allen-Bradley CompactLogix, Siemens SINAMICS drives, PanelView HMIs, and more—so you can modernize without forced rip-and-replace.
Myth 4: Automation Increases Downtime Risk
More automation doesn’t mean more breakdowns. Modern systems predict failures earlier, recover faster, and reduce human error. Real risk comes from not planning—no spares, no recovery kits, no preventive strategy.
IAC connection: Downtime myths crumble with preparation. Industrial Automation Co. offers pre-built 48-hour recovery kits and same-day shipping on drives, CPUs, and HMIs—so you’re never waiting when every hour counts.
Myth 5: Only Big Players Like Amazon Can Do It Right
Amazon’s automation is impressive, but automation adoption is mainstream. Scalable options exist for every plant size. Smaller manufacturers often see the fastest payback because improvements immediately hit throughput, quality, and safety.
- 60% of companies had implemented some form of automation by 2024—and adoption is rising. Journal of Accountancy
- The global Industrial IoT market is large and expanding, reflecting broad participation beyond mega-corps. MarketsandMarkets
Myth 6: Once Installed, Automation Runs Itself
Automation isn’t “set it and forget it.” It needs ongoing training, support, and maintenance—firmware updates, operator refreshers, power monitoring. Plants that treat automation as a living system see the best reliability.
- Over two-thirds of industrial businesses face unplanned outages monthly, averaging $125,000/hour. ABB
- Trade coverage corroborates high downtime costs across manufacturers. Plant Services
Myth 7: Automation Is Too Complex to Maintain
Modern platforms are designed for usability and remote diagnostics. With vendor support and structured training, automated systems are often easier to maintain than aging legacy equipment—and can even prevent failures before they occur.
- Predictive maintenance enabled by automation can reduce maintenance costs by ~25% and cut breakdowns by up to 70%. World Economic Forum (with Deloitte)
- Skills and capability remain a top barrier—underscoring the need for training and support programs. Deloitte Insights
Conclusion: Bust the Myths, Protect Your Plant
The truth behind these seven myths is simple: automation delivers when it’s paired with the right parts, training, and support. Manufacturers who embrace the facts gain productivity, reduce downtime, and build a stronger future.
How Industrial Automation Co. helps:
- Same-day shipping on drives, PLCs, HMIs, and CPUs
- Legacy + current-gen parts so you can modernize at your pace
- Pre-built recovery kits to cut downtime from days to hours
Ready to cut through the myths and protect your plant from costly downtime? Explore IAC’s catalog of servo drives →
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