Collaborative Robot Automation
Human-Centric. Real Results.
Collaborative robots (Cobots) for safer, smarter lines. Engineered for Uptime and ROI. Automation That Pays for Itself. Future-Proof Your Operations. Smarter Systems. Safer Workplaces.
1Average payback period for automation projects $100k-$250k based on 2024-2025 client deployments. Actual results vary by application.
Why Choose Stewart Industrial Automation
We specialize in collaborative robot integration, PLC programming, and industrial automation solutions for manufacturing operations in Ohio and beyond. With expertise in leading brands like Fanuc, Universal Robots, ABB, KUKA, and Yaskawa, we deliver fast-payback automation projects designed for real production environments. Our remote deployment capabilities and 48-hour response guarantee ensures your lines stay running while we implement human-centric automation that enhances—not replaces—your workforce.
Real Lines. Real Results.
BMW Regensburg Plant
AI-based visual inspection for final assembly
→ Automated defect detection
→ 100% inspection coverage
→ 5% reduction in rework costs
Source: BMW Group Press Release 2021 (link)
Coca-Cola Bottling
Digital twin for bottling line optimization
→ Real-time simulation and monitoring
→ 20% increase in throughput
→ 9% reduction in energy use
Source: Siemens Digital Industries 2022 (link)
Pfizer Manufacturing
MES automation for vaccine production
→ Automated batch record management
→ 30% faster batch release
→ Improved regulatory compliance
Source: Rockwell Automation & Pfizer 2021 (link)
Your Personal Payback Estimate
💼 Professional ROI Analysis
CFO-approved methodology used by leading automation providers. All assumptions are transparent and conservative.
💰 Section 1: One-Time Investment (CapEx)
Robot System Configuration
Additional Equipment & Hardware
Adjust percentages based on your application complexity (shown as % of robot base cost)
Grippers, vacuum, welding torch, etc.
Cost:
Feeders, conveyors, vision, sensors
Cost:
Fencing, light curtains, safety PLC
Cost:
Power, compressed air, networking
Cost:
Stewart IA Engineering & Integration Services
Auto-calculated based on project complexity. Integration costs scaled: 1-3 lines (100%), 4-6 lines (95%), 7+ lines (90%).
Discovery & Assessment
Solution Design & Build
Testing & UAT
Deployment & Change Mgmt
Training & Handoff
Project Management (10%)
💰 Total Installed Cost
Installed cost multiplier: robot base price (Industry typical: 2.0-5.0x)
📊 Section 2: Annual Operating Costs (OpEx)
Ongoing costs to maintain and operate your automation system.
% of total installed cost
Per robot per year
% of robot cost
Welding wire, gripper fingers, etc.
Typical range: 7-10% of installed cost annually
💎 Section 3: Annual Benefits & Savings
Quantifiable value delivered by automation. Adjust based on your specific situation.
Direct Labor Savings
Wages + benefits + overhead
Annual Direct Labor Savings:
Indirect Labor Reduction
Typical: 0.2-1.0 FTE per cell
Annual Indirect Labor Savings:
Productivity / Throughput Gains
Due to faster cycle time
Annual Productivity Gain:
Quality Improvements
Total Quality Savings:
Scrap: $ + Rework: $ + Warranty: $
Changeover Time Reduction
Fully loaded plant cost per hour
Annual Changeover Savings:
Safety & Workers Compensation
0.1 = 10% chance per year
$50k-$500k typical
Annual Safety Savings:
💎 Total Annual Benefits
🎯 Section 4: ROI Summary Dashboard
Industry-standard ROI analysis. All calculations are transparent and conservative.
Total Installed Cost: Robot Cost + EOAT + Peripherals + Safety + Infrastructure + Stewart IA Services
Annual OpEx: Maintenance + Electricity + Software Support + Consumables
Annual Benefits: Direct Labor + Indirect Labor + Productivity + Quality + Changeover + Safety
Net Annual Cash Flow: Total Annual Benefits − Total Annual OpEx
Simple Payback: Total Installed Cost ÷ Net Annual Cash Flow (in years)
5-Year ROI: [(Benefits × 5) − (CapEx + OpEx × 5)] ÷ Total Investment × 100
💎 Quantifiable Annual Benefits
Total Installed Cost
CapEx investment
Annual Net Cash Flow
Benefits minus OpEx
Simple Payback
✓ Under 1 year!
5-Year ROI
Return on investment
🎯 What This Means for Your Business
Year 1 Net Benefit
After CapEx & OpEx
Installed Cost Multiplier
Total cost per robot dollar
3-Year Cumulative Benefit
Total profit after all costs
Frequently Asked Questions
How much does industrial automation cost?
Typical collaborative robot deployments range from $75,000 to $250,000 depending on application complexity, integration requirements, and peripheral equipment. Our ROI calculator above provides a customized estimate based on your specific production environment. Most clients see payback within 12-18 months.
What robot brands do you work with?
We integrate robotics from all major manufacturers including Fanuc, Universal Robots (UR), ABB, KUKA, Yaskawa (Motoman), Kawasaki, and DENSO. We recommend the best fit for your application based on payload, reach, precision requirements, and budget—not brand loyalty.
How long does a typical automation project take?
From assessment to commissioning, most cobot integrations take 8-16 weeks. This includes design, procurement, programming, installation, and operator training. We offer remote deployment and programming to minimize on-site disruption. Rush projects are available for critical production needs.
Will automation replace my workers?
No. Our philosophy is human-centric automation—cobots handle repetitive, dangerous, or ergonomically challenging tasks while your skilled workers focus on problem-solving, quality control, and value-added activities. Most clients redeploy workers to higher-skill roles rather than reducing headcount.
Do you provide training and ongoing support?
Yes. Every project includes comprehensive operator and maintenance training. We offer ongoing support packages with remote diagnostics, software updates, and a 48-hour response guarantee. Our goal is to make your team self-sufficient while providing backup when needed.
What industries do you serve?
We specialize in automotive assembly, food and beverage processing, pharmaceutical manufacturing, and general industrial production. Our solutions are tailored to meet industry-specific requirements including automotive ISO/TS standards, FDA compliance for pharmaceuticals, and food-grade certifications.