Automation & Robotics: Future of UK Manufacturing

Why Robotics and Automation Are Non-Negotiable for UK Manufacturing’s Future

In today’s hyper-competitive global market, standing still equates to falling behind. For UK manufacturers, confronting unpredictable costs, labor shortages, and sustainability targets requires a fundamental shift. According to Mike Wilson, a preeminent voice in industrial automation with four decades of experience, that shift must be towards robotics and integrated automation solutions. He will champion this message at the Automation in Action panel at Packaging Innovations & Empack 2026.

The Stubborn Gap in UK Automation Uptake

Despite growing awareness, tangible progress lags. Wilson observes that robot deployment rates in the UK have plateaued, widening the gap with leading manufacturing nations. This hesitation threatens long-term productivity and market share. However, a promising change in the political and economic dialogue, recognizing manufacturing’s core value to the economy, is creating a more fertile ground for investment.

Breaking Down Barriers: Cost, Culture, and Complexity

Resistance to factory automation is multifaceted. Beyond upfront costs, a pervasive “make-do” culture and risk aversion, especially within SMEs, stifle investment. A prevalent myth persists that robotics and PLC systems are only viable for massive, high-volume production lines.

The knowledge deficit is equally critical. Business owners often lack the framework to specify, justify, and procure automation—skills not taught in traditional apprenticeships or business courses. This creates an imbalance during vendor discussions. Therefore, accessing independent expertise, like that offered by the MTC, is essential for building a credible business case and starting with manageable, high-ROI projects.

Solving the People Equation with Technology

Demographics add urgency. An aging workforce—with the average UK manufacturing employee over 50—poses a severe skills cliff. Simultaneously, attracting new talent demands modern, tech-centric workplaces. The next generation are digital natives; they seek roles involving analytics, system control, and AI. Strategic automation creates these roles, moving human workers from repetitive tasks to oversight and continuous improvement. This evolution also makes the industry more accessible and appealing to a diverse workforce, breaking down traditional gender barriers in engineering.

A Pragmatic Roadmap for Automation Success

Avoiding common pitfalls is crucial. Wilson warns against first automating the most complex, problematic process—the primary bottleneck. The associated learning curve can be daunting. A smarter approach begins with dull, dirty, or repetitive tasks. Automating areas like consistent palletizing or machine loading frees skilled personnel for higher-value work and builds operational confidence. The real gain from systems like DCS or robotic cells isn’t always raw speed, but unwavering consistency and 24/7 reliability, which optimizes overall equipment effectiveness (OEE).

The Integral Role of AI and Embedded Intelligence

The future is intelligent automation. AI is already enhancing manufacturing not as humanoid robots, but as embedded software improving predictive maintenance, adaptive control, and simplifying programming. This “invisible” AI lowers the barrier to entry, making systems more flexible and user-friendly. Businesses must develop a strategic automation roadmap aligned with 5–10 year goals, integrating necessary training and phased technology investments from the outset.

Packaging: A Prime Sector for Automation Gains

The packaging industry, characterized by high volume, fast changeovers, and labor intensity, presents a compelling case for automation. The productivity gains directly address tight margins and fierce competition. Wilson asserts that by 2030, automation will be the key differentiator between industry leaders and those struggling to survive. It is the fundamental lever for improving productivity, which in turn enables better wages, talent attraction, and reinvestment.

Expert Commentary and Analysis

The conversation must move from “if” to “how” to automate. The UK’s strength in innovation and high-value manufacturing can be amplified by a wave of digital transformation. My analysis aligns with Wilson’s: the convergence of accessible robotics, cloud-based SCADA systems, and AI-driven analytics creates a unique window for SMEs. The most successful manufacturers will be those who view automation not as a mere capital expense, but as the core of their operational strategy and talent value proposition.

Practical Application Scenarios

• Scenario 1: SME Food Packaging: A mid-sized producer implements a collaborative robot (cobot) for primary pack case loading. The cobot’s simplicity allows existing line operators to be trained as programmers. The result is a 30% reduction in manual handling injuries and the reallocation of staff to quality inspection roles, improving output quality.
• Scenario 2: Automotive Components: A supplier installs a vision-guided robotic cell for precise component assembly, integrated with their existing PLC control system. This not only improves throughput by 25% but also provides traceability data for each part, enhancing compliance with stringent industry standards.

Frequently Asked Questions (FAQs)

Q1: Is automation only financially feasible for large manufacturers?

A: No. The rise of modular, scalable solutions like cobots and compact PLC systems has dramatically lowered entry costs. Payback periods for well-chosen SME projects can now be under 18 months.

Q2: Will automation lead to significant job losses?

A: Historically, automation redefines jobs rather than eliminating them en masse. It addresses the critical shortage of people willing to perform highly repetitive tasks and creates demand for more technical roles in programming, maintenance, and data analysis.

Q3: How do I start if I have no in-house expertise?

A: Begin with a focused audit from an independent advisor. Identify one or two processes that are repetitive and stable. Utilize government support schemes and partner with integrators who offer extensive training and support packages.

Q4: What’s the difference between PLC, DCS, and SCADA in simple terms?

A: Think of a PLC as the reliable computer controlling a specific machine or process line. A DCS is a network of controllers managing an entire large, complex plant. SCADA is the supervisory software that collects data from PLCs and DCS, providing the human-machine interface (HMI) for monitoring and control.

Q5: How crucial is AI in modern industrial automation?

A: AI is becoming a key enhancer. It’s used for predictive maintenance (forecasting machine failure), vision systems for quality inspection, and optimizing production schedules in real-time. It makes systems smarter and more adaptive.