Our expertise extends across the entire technology
spectrum including emerging technologies

How to Streamline Manufacturing Operations through Process Automation Solutions

  • RPA Solutions


How do you reconcile between these two contrasting global realities? On the one hand, China beats the US hands down with a trade deficit of USD 279 billion thanks to automation in the manufacturing sector. On the other hand, China ranks 13th among 27 countries in terms of readiness for intelligent automation.


This blog will examine the core of process automation in manufacturing operations and evaluate ways to revolutionize them. We will also evaluate the difference between industrial automation and intelligent automation and how process automation solutions can raise productivity, unlock opportunities, and realize their full potential.


What if we told you that we all waste more money than we earn? Manual production processes account for 90% of errors, increasing the overall cost of the products. Manufacturers transfer these losses to customers. In the post-covid era, emphasis is on reducing cost, enhancing precision, and improving speed.


Process automation solutions take over repetitive tasks, reduce errors, improve productivity, increase production speed, and enhance quality to meet market demands. Consequently, automation streamlines manufacturing operations, improves customer experiences, and improves revenue streams.
The Bottlenecks of Manual Manufacturing


When businesses identify bottlenecks, they often stem from multiple sources. These challenges arise through overlapping production processes, inadequate workflows, old machinery, or ineffective resource management.

What is a bottleneck in manufacturing?

When people, processes, and production slow down, a complex web of challenges is created. When not negotiated skillfully, these challenges result in permanent bottlenecks.


According to ABPMP guidelines, bottlenecks are “capacity constraints that create a backlog. Usually, these constraints prevent the system from achieving more of its goals.” These manufacturing process bottlenecks can be short-term or long-term, external or internal; they erode business confidence, interrupt production flow, and reduce profitability.


blog sub img

What impacts are caused by bottlenecks?

Being agile, meeting market demands, exploring new markets, delivering quality products on time, and winning over competition have become prerequisites for manufacturing businesses. However, none of these objectives can be feasible unless operational hurdles are removed. The impact of manual manufacturing bottlenecks could be wide-ranging if not addressed immediately and adequately.

Quality degradation:

Manual processes are always inconsistent and prone to defects. Robotic process automation helps businesses bring consistency for quality consistency.

Low Productivity:

Maintaining equal motivation levels in people is difficult. However, AI and automation solutions can work around the clock without affecting productivity.

High Error Count:

Manual operations increase error vulnerabilities. Process automation solutions reduce, detect, and resolve errors quickly and efficiently.

Strained Workflow:

Manual processes stretch workflow beyond its elasticity. An AI development company always focuses on workflow automation to reduce strain.

Inefficient Insights:

Manual operations almost prevent data generation and analysis. In contrast, automation records each piece of data accurately and provides precise insights.

Overburned machinery:

Outdated machinery is overused to meet demands, leading to downtime. Intelligent process automation optimizes machine usage and extends its life.

Internal Conflicts:

Miscommunication leads to conflicts and disasters. Business process automation maintains the communication flaw for enhanced productivity.

Major Financial Losses:

Fractured manufacturing processes often lead to mistakes and financial losses. Process automation protects profitability by reducing costs and mitigating risks.

Common Manufacturing Bottlenecks

Repetitive Tasks:

When men are involved in repetitive tasks, saturation time comes quickly and slows the process. Robotic Process Automation (RPA) ensures businesses place their workforce strategically in more productive work.

Unskilled Employees:

Incompetent employees are prone to errors, and training new employees is expensive. AI and automation solutions empower employees to simplify work and automate tasks.

Ill-defined Processes:

Overlapping and ambiguous workflows cause delays and rework. Process automation solutions standardize task processes, enhance consistency, and improve performance.

Machine Capacity:

Inefficient and outdated machinery hinders scalability and limits production capabilities. AI development companies deliver AI solutions that optimize usage and predict maintenance.

Lack of Insights:

Without wide-ranging data and accurate analysis, decision-making is impaired. AI and automation solutions extract and analyze data into insights for market-oriented decision-making.

Lack of Automation:

Manual processes invite more mistakes and slow turnaround. Robotic process automation automates tasks, improves proficiency and accuracy, and consistently delivers peak performance.

The Benefits of Process Automation

Increased Productivity:

One of the primary objectives of automation is to eliminate manual work and transfer the same workforce to value-added tasks, increasing production speed and output.

Enhanced Transparency:

Since automation is auditable and traceable, it gives real-time visibility into processes and the decision-making behind them to improve operational control and accountability.

Improved Standardization:

Deviations in business processes affect execution and product quality. Automation performs each task with the utmost consistency, which helps businesses set process standards.

Reduced Costs:

When human efforts are reduced and machines are deployed, productivity and production increase, resulting in massive cost savings. Moreover, it reduces mistakes and rework.

Employee Satisfaction:

Employees are set free from daily repetitive tasks and placed to perform more creative and impactful work. More meaningful work enhances employees’ focus and satisfaction levels.

Reduced Errors:

Inconsistent human actions are always vulnerable and prone to errors. Automation, on the other hand, is consistent, detects and resolves errors, and prevents reoccurrences.

Increased Scalability:

Human performance is limited. Besides, businesses can’t escalate or reduce as needed. Automation enhances adaptability and optimizes processes to be future-ready.

Improved Compliance:

The manufacturing sector attracts many regulations, and non-adherence invites penalties. Since automation standardizes business processes, consistently following regulations becomes easy.

Enhanced Accuracy and Precision:

When automation performs tasks, there is a hyperlevel of consistency. Consequently, automation delivers outcomes with extreme accuracy and utmost precision compared to manual processes.

Significant Time Savings:

Along with costs, automation saves businesses a lot of work hours. It also increases production speed and reduces errors. Streamlining workflow increases business capacity to meet market demands.

The Future of Process Automation:

Investment in process automation solutions keeps small and medium manufacturing businesses at bay as yet. However, mega-manufacturing businesses are heavily investing in robotic process automation and AI-powered intelligent automation to build a smart future for the manufacturing sector.


As businesses grow and AI becomes more feasible, small and medium businesses will also adapt to AI and automation solutions, paving the way for hyper-automation. The future of manufacturing rests on the highly sophisticated integration of AI/ML solutions to ensure that even unstructured and scattered data is effectively analyzed, natural language processing is leveraged for hyper-engagement, and entangled business processes are simplified. We can truly visualize RPA-as-a-Service in the near future.

How Can Sigma Solve Help?

Sigma Solve stays at the forefront of building customized process automation solutions for various sectors. Our AI and automation experts have developed a knack for data analytics, AI algorithms, machine learning models, LLPs, NLP, and many other automation techniques. These techniques help businesses reduce their operation costs and gain much-needed insights into their business, sector, and market to strategize growth.


Sigma Solve has successfully transformed top-notch businesses through AI and automation, adding more capabilities, enhancing efficiency, streamlining business processes, and improving revenue streams. Consult with our AI and automation experts to acquire new capabilities and set a progressive path for your business into the future with ever-evolving benefits. Call us at +1 954-397-0800 for consultations.

Table of Contents

Don’t Miss Out