Did You Know? Automation in Manufacturing Isn’t About Replacing People

Based on the Did You Know Video: Automation at Onanon By Dennis Johnson, General Manager & Chief Technology Officer and Jared Sinasohn, Mechatronics Engineer

Automation is one of the biggest challenges OEMs and manufacturers face today.

Not because automation does not work, but because it is difficult to get right.

Many companies attempt to automate production processes, only to encounter new problems. Quality becomes inconsistent. Costs increase instead of decrease. And in some cases, manufacturers revert back to manual processes after failed automation efforts.

So what separates effective automation from failed automation?

The answer is not just technology. It is philosophy.

Why Automation Fails in Manufacturing

Automation is often approached as a way to replace labor. But when automation is implemented without a clear strategy, it can introduce more complexity than it removes.

Common challenges include:

• Difficulty maintaining consistent quality

• High upfront investment without predictable ROI

• Inflexible systems that cannot adapt to product variation

• Increased troubleshooting and downtime

• Loss of process control

When automation is poorly implemented, manufacturers may find themselves spending more time managing machines than producing parts.

The Hidden Cost of Manual Processes

At the same time, relying too heavily on manual assembly introduces its own risks.

Repetitive, high-precision tasks place strain on operators over time. As fatigue increases, the likelihood of errors rises.

This can lead to:

• Inconsistent assembly quality

• Increased rework and scrap

• Lower throughput

• Higher training requirements

• Greater variability across production runs

In high-volume or precision-driven environments, even small inconsistencies can have significant downstream impact.

Hear more about Jared Sinasohn’s piece here

A Better Approach: Automation That Supports People

At Onanon, automation has been developed over decades with a different goal:

Not to replace people, but to support them.

True automation improves both production performance and the operator experience. It removes repetitive strain, reduces opportunities for error, and allows skilled workers to focus on higher-value tasks.

When implemented correctly, automation:

• Improves consistency and repeatability

• Reduces operator fatigue

• Enhances overall product quality

• Stabilizes production costs

• Increases throughput without increasing labor strain

The result is not just better products, but a better working environment. Employees have better morale, less train and high quantity and quality outputs. We have employees who have been with Onanon since it started, over 37 years ago.

Precision Automation in Connector and Cable Assembly

In applications such as medical connectors, custom cable assemblies, and connectorized PCBs, precision is critical.

To support these requirements, Onanon has developed proprietary automation technologies, including:

• Automated pin loading systems for high-density connector assemblies

• Robo Solder processes for consistent, repeatable soldering

• Custom automation platforms tailored to connectorized designs

These systems are engineered specifically for the unique challenges of electromechanical assemblies, where precision, alignment, and repeatability are essential.

Why Automation Improves Quality

When automation is applied to the right processes, it removes variability.

Unlike manual processes, automated systems can:

• Maintain consistent positioning and force

• Repeat tasks with exact precision

• Eliminate variability between operators

• Operate continuously without fatigue

This leads to higher yields, fewer defects, and more predictable production outcomes.

For OEMs, that translates directly into improved reliability and lower total cost of ownership.

Watch Onanon’s specific automation in action

Automation and Workforce Experience

A key misconception is that automation reduces the role of people in manufacturing.

In reality, the opposite is true.

Well-designed automation allows operators to:

• Focus on oversight rather than repetitive tasks

• Work in safer, less physically demanding environments

• Contribute to higher-value activities

• Maintain consistent performance throughout production shifts

Automation becomes a tool that enhances human capability, rather than replacing it.

The Future of Manufacturing Automation

As products become more complex and production volumes increase, the role of automation will continue to grow.

However, success will depend on how automation is implemented.

The most effective manufacturers will focus on:

• Process-driven automation strategies

• Human-centered design

• Scalable, adaptable systems

• Integration with product design and manufacturability

Automation is not a one-size-fits-all solution. It must be engineered with the same level of care as the product itself.

Engineering Automation That Works

If you are evaluating automation for medical connectors, custom cable assemblies, or connectorized PCB production, early engineering collaboration is critical.

At Onanon, automation is developed alongside product design to ensure manufacturability, scalability, and long-term reliability.

Visit Onanon.com to learn more or connect with an engineer to explore how automation can improve your production processes.

is one of the biggest challenges OEMs and manufacturers face today.

Not because automation does not work, but because it is difficult to get right.

Many companies attempt to automate production processes, only to encounter new problems. Quality becomes inconsistent. Costs increase instead of decrease. And in some cases, manufacturers revert back to manual processes after failed automation efforts.

So what separates effective automation from failed automation?

The answer is not just technology. It is philosophy.

Why Automation Fails in Manufacturing

Automation is often approached as a way to replace labor. But when automation is implemented without a clear strategy, it can introduce more complexity than it removes.

Common challenges include:

• Difficulty maintaining consistent quality
• High upfront investment without predictable ROI
• Inflexible systems that cannot adapt to product variation
• Increased troubleshooting and downtime
• Loss of process control

When automation is poorly implemented, manufacturers may find themselves spending more time managing machines than producing parts.

The Hidden Cost of Manual Processes

At the same time, relying too heavily on manual assembly introduces its own risks.

Repetitive, high-precision tasks place strain on operators over time. As fatigue increases, the likelihood of errors rises.

This can lead to:

• Inconsistent assembly quality
• Increased rework and scrap
• Lower throughput
• Higher training requirements
• Greater variability across production runs

In high-volume or precision-driven environments, even small inconsistencies can have significant downstream impact.

A Better Approach: Automation That Supports People

At Onanon, automation has been developed over decades with a different goal:

Not to replace people, but to support them.

True automation improves both production performance and the operator experience. It removes repetitive strain, reduces opportunities for error, and allows skilled workers to focus on higher-value tasks.

When implemented correctly, automation:

• Improves consistency and repeatability
• Reduces operator fatigue
• Enhances overall product quality
• Stabilizes production costs
• Increases throughput without increasing labor strain

The result is not just better products, but a better working environment.

Precision Automation in Connector and Cable Assembly

In applications such as medical connectors, custom cable assemblies, and connectorized PCBs, precision is critical.

To support these requirements, Onanon has developed proprietary automation technologies, including:

• Automated pin loading systems for high-density connector assemblies
• Robo Solder processes for consistent, repeatable soldering
• Custom automation platforms tailored to connectorized designs

These systems are engineered specifically for the unique challenges of electromechanical assemblies, where precision, alignment, and repeatability are essential.

Why Automation Improves Quality

When automation is applied to the right processes, it removes variability.

Unlike manual processes, automated systems can:

• Maintain consistent positioning and force
• Repeat tasks with exact precision
• Eliminate variability between operators
• Operate continuously without fatigue

This leads to higher yields, fewer defects, and more predictable production outcomes.

For OEMs, that translates directly into improved reliability and lower total cost of ownership.

Automation and Workforce Experience

A key misconception is that automation reduces the role of people in manufacturing.

In reality, the opposite is true.

Well-designed automation allows operators to:

• Focus on oversight rather than repetitive tasks
• Work in safer, less physically demanding environments
• Contribute to higher-value activities
• Maintain consistent performance throughout production shifts

Automation becomes a tool that enhances human capability, rather than replacing it. An example we have of this is RoboSolder, automated robotic fine wire termination: Robosolder® Automated Fine Wire Termination

The Future of Manufacturing Automation

As products become more complex and production volumes increase, the role of automation will continue to grow.

However, success will depend on how automation is implemented.

The most effective manufacturers will focus on:

• Process-driven automation strategies
• Human-centered design
• Scalable, adaptable systems
• Integration with product design and manufacturability

Automation is not a one-size-fits-all solution. It must be engineered with the same level of care as the product itself.

Engineering Automation That Works

If you are evaluating automation for medical connectors, custom cable assemblies, or connectorized PCB production, early engineering collaboration is critical.

At Onanon, automation is developed alongside product design to ensure manufacturability, scalability, and long-term reliability.

Visit Onanon.com to learn more or connect with an engineer to explore how automation can improve your production processes.