There are times when automation is simply essential because of scale or complexity. Projects requiring millions of parts per year often justify upfront investment in automation thanks to the long-term gains in speed, consistency, and cost. 

"Volume matters, but it's not the only factor," explains Jeffrey Huijerjans, one of Rompa's automation experts. "Sometimes it's about feasibility. We have projects where manual handling isn't just inefficient, it's physically impossible or forbidden. One of our current medical projects, for instance, prohibits human contact with the parts altogether. That makes automation non-negotiable." 

Safety and compliance requirements can also drive the decision. Laser-based processes, for example, introduce occupational hazards that require shielding and automated control. "Operators can't be looking directly at a laser," says Jeffrey. "Even with lower volumes, automation is needed to make the process safe." 

In other cases, tight tolerances or multi-part assembly tasks make full automation a clear advantage. For one fully automated line that produces over 9 million parts annually, Rompa integrates mold ejection, robotic transfer, real-time inspection using cameras and lasers, and automated packaging into one seamless, automated flow. "When every micron counts, and every part must meet exact specs, humans can't deliver that kind of repeatability," Jeffrey adds. 

"We don't just push full automation from day one," says Vincent Gerard, Supply Chain Manager. "We explore the production logic with each customer. Sometimes we'll show them a menu of options — fully automated, semi-automated, or manual — and map out the price, flexibility, and risk associated with each." 

For many of Rompa's customers, hybrid solutions also offer better ROI — especially when budget limits, uncertain demand, or technical unknowns make full automation too risky. 

"There was one automotive project where we could have built a fully automated line for around €1 million," says Jeffrey. "Instead, we created a semi-automated solution for just €200,000. Human operators transferred parts between stations, but every process step was still controlled, measured, and traceable." 

There are many cases like this where manual handling remains the pragmatic choice. For low- to medium-volume products or those with high variability, humans offer agility that machines can't match (yet). Blending manual labor into otherwise automated lines can be a cost-effective compromise that still supports high quality and traceability through embedded sensors and inspection steps. 

The menu approach to automation also helps accommodate project ramp-ups, where volumes grow over time. "It's not always smart to go full throttle at the start," Vincent notes. "If the concept hasn't been proven, it makes more sense to validate key steps with semi-automation, then scale up later. It's a way to manage risk without compromising long-term goals." 

Put another way: In early-stage product development or market launches, flexibility can outweigh speed. "Sometimes a customer thinks they need full automation," says Vincent. "But once we map the costs and challenges, it's clear a more incremental approach is smarter — it allows learning and adaptation without locking into high-cost infrastructure." 

"It's important to say that manual labor is not 'less than' automation," adds Vincent. "It's a tool in the toolbox. What matters is using the right tool in the right place." 

So, how do you measure the benefits of automation? It can be tempting to evaluate just one metric: how many parts per hour can it produce? But the real return on investment in automation goes far beyond speed. 

"Customers tend to fixate on the upfront investment," says Vincent. "But the real value often lies in reduced scrap, improved quality, and data-driven decisions. These drive down total cost of ownership." 

Rompa helps customers look beyond just cycle time and consider a broader range of ROI factors: 

• Product quality: Automation ensures precision across every part, every shift. This reduces downstream costs. 

• Traceability: With cameras, sensors, and software logging each step, Rompa's automated lines create a digital fingerprint for every part — particularly valuable in regulated industries such as automotive and life sciences. 

• Predictive maintenance: In some lines, smart sensors monitor tooling and machine health in real time. "If process parameters start drifting, we can flag issues before they become failures," says Jeffrey. "It reduces unplanned downtime and protects both product integrity and a reliable supply chain." 

Scalability also plays a major role. Automated setups can grow with demand — a factor that's critical for customers planning long-term product lifecycles. "You might start with semi-automation for the first 50,000 parts," Vincent explains, "then scale to full automation once the product gains traction." 

Customers frequently expect a guarantee of faster production, lower costs, and flawless quality when they invest in automation, but that's not always how it works out. "One of the biggest misconceptions is that automation always saves money," says Jeffrey. "In reality, it can sometimes increase costs, especially when the volume isn't there, or when a product still needs development work." That's why it's important to be pragmatic about when to automate or not. 

Another common pitfall is overestimating how quickly a fully automated solution can be delivered. "Designing and building an automated line takes time," Vincent explains. "You can't just plug in a robot and go. There are engineering phases, testing, and fine-tuning. If you haven't validated the process first, you risk costly delays." 

Rompa helps customers avoid these traps by acting as a strategic automation partner rather than just a supplier. From the earliest design discussions to the final commissioning, Rompa provides a tailored automation roadmap that balances ambition with practicality. And it all starts with listening.  

"We don't sell off-the-shelf solutions," says Vincent. "We sit down with the customer and understand their goals, budget, and technical needs and discuss the impact of the different options on risk, cost, and flexibility." 

This consultative approach is backed by Rompa's ability to deliver the full automation journey in-house. From early design and prototyping to CAD drawings, software specifications, and factory integration, Rompa manages the process from start to finish — with a single project manager for consistency and accountability. 

"We're not just buying robots," says Jeffrey. "We design systems that are integrated with molding, testing, packaging, and even ERP data flows. Everything is tailored to the customer's product and production environment." 

The result? Fewer surprises. Better outcomes.  

Smart manufacturers match automation levels to project goals, risk profiles, and commercial realities. 

At Rompa, we help you make the right choice — whether that's full automation, semi-automation, or a flexible mix that evolves as your product does. 

Want a clearer picture of your automation options? 
Book a meeting to discuss your next project with one of our engineers. 

[Get in Touch]