What Manufacturers Should Know Before Investing in a Custom Automation Machine
Investing in a custom automation machine is a major decision for manufacturers looking to increase throughput, improve quality, reduce labor costs, and modernize their industrial automation systems. Manufacturers exploring automation often have the same core questions:
How much will it cost? How long will it take? What kind of performance should we expect?
The right custom automation partner can design anything from a standalone custom assembly machine to fully integrated automated production lines. Whether you’re evaluating automated assembly machines, industrial automation systems, or a fully turnkey production line, understanding cost, ROI, cycle time, and project timelines is critical.
This FAQ guide answers the most common questions manufacturers ask before partnering with a custom automation machine builder.
What is a custom automation machine?
A custom automation machine is purpose-built equipment designed specifically for a product, process, or manufacturing requirement. These automated manufacturing machines are engineered by a custom machine builder to integrate seamlessly in a manufacturing facility as a standalone system or function as part of a larger automated production line.
Unlike off-the-shelf equipment, custom machines are engineered around:
- Unique part geometries
- Required cycle times
- Quality or inspection requirements
- Production volumes
- Factory layout constraints
They are commonly used in industries such as:
- Electrical and electronic devices
- Lifesciences and medical devices
- Consumer products
- Industrial components
- Automotive and aerospace
When does a manufacturer need a custom machine?
Custom automation is typically the right choice when:
- Manual assembly is labor-intensive or inconsistent
- Production volume is increasing
- Quality or traceability requirements are tightening
- Existing equipment cannot meet speed or precision targets
- The product design is unique or constantly evolving
In these cases, off-the-shelf automated assembly machines often lack the flexibility or performance required, making a custom automation machine the better long-term solution. Companies often pursue custom automation to gain a competitive advantage through:
- Higher throughput
- Reduced labor
- Improved quality and consistency
How much does a custom automation machine cost?
Automation machine cost varies based on complexity, speed, integration level, and the number of stations.
Across the industry, typical ranges are:
- Single-station or focused machines: about $200,000+
- Multi-station assembly systems: $800,000–$1.5 million
- Large turnkey production lines: $1.5 million or more
Many integrators note that custom automation projects frequently fall into the six- or seven-figure range depending on scope. The total automation machine cost is influenced by robotics, controls architecture, vision systems, part feeding technology, and the level of automated test and inspection required.
How long does it take to build a custom machine?
Project timelines depend on complexity, validation requirements and any long-lead time purchased components like robots, vision systems or lasers.
Typical SDC ranges:
- Simple systems: 16-20 weeks
- Mid-complexity machines: 20-36 weeks
- Complex multi-station lines: 36-50+ weeks
A large project timeline is often divided roughly into:
- 25% design and procurement
- 25% mechanical and electrical build
- 25% debugging and testing
- 25% run-off, installation, and training
What cycle times can a custom assembly machine achieve?
Cycle time depends on part complexity, number of operations, and system architecture. High-speed assembly applications require optimized tooling, advanced motion control, and carefully engineered feeding systems to achieve maximum parts per minute (PPM).
Low-speed / high-complexity assemblies
- 2–10 PPM (parts per minute)
- Many components
- Tight tolerances or inspections
Standard high-volume assembly
- 15–60 PPM
- 2–6 components
- Typical rotary or inline systems
High-speed consumer or connector-type products
- 60–150+ PPM
- Simple operations
- Optimized feeding and tooling
Ultra-high-speed micro-assembly
- 150–1,000+ PPM
- Very small parts
- Continuous motion or multi-up tooling
Important Context (What Actually Determines PPM)
Cycle time is driven primarily by:
- Number of assembly steps
- Part presentation method (vibratory, centrifugal, tray, etc.)
- Tolerance and precision requirements
- Inspection and testing time
- Number of parts produced per cycle (multi-up tooling)
For example:
- A 2-component snap-fit may run at 80–120 PPM.
- A 12-component medical device with testing may run at 8–15 PPM.
What kind of ROI should we expect?
ROI depends on labor savings, quality improvements, and throughput increases.
Common results from custom automation projects:
- Annual savings of $300k–$450k in labor alone
- Payback periods of 1–2 years for many systems
Some high-volume, multi-shift operations achieve payback in under a year.
Why the Investment Makes Sense: Understanding Automation ROI
Typical ROI drivers include:
- Replacing 2–6 operators per shift
- 30–50% throughput increases
- 3–8% improvements in first-pass yield
ROI Example:
A $950,000 custom automation machine replaces four operators per shift across two shifts, reducing annual labor costs by approximately $390,000. With additional savings from scrap reduction and improved throughput, the total annual financial impact can reach $450,000–$500,000. At that rate, the system achieves payback in roughly 18–24 months. In higher-volume or three-shift operations, payback is often even faster. After full payback, the machine continues generating cost savings and capacity gains for years.
When evaluating the ROI of industrial automation, manufacturers typically analyze labor savings, scrap reduction, throughput gains, and long-term scalability. In many cases, full payback occurs in 18–24 months for high-volume operations.
What information does a machine builder need to quote a project?
Most custom machine builders and automation system integrators require:
- Part drawings or samples
- Annual production volume
- Required cycle time
- Quality or inspection requirements
- Available floor space
- Budget expectations
Production volume and speed targets have a major impact on cost and design complexity. Here’s a more detailed list on what to provide.
What happens during a custom automation project?
SDC has a rigid project management process designed to keep our customers in the loop throughout the lifecycle of each project, most follow these general phases:
- Discovery and feasibility
- Concept development and proposal
- Detailed design
- Machine build
- Debug and factory acceptance testing
- Installation and commissioning
- Training and support
A disciplined process ensures the custom automation machine builder delivers a reliable automated manufacturing machine that meets performance, quality, and safety standards.
Can custom machines handle very small or delicate parts?
Yes. Many custom automation systems are specifically designed for:
- Small plastic or metal components
- Electrical connectors and terminals
- Medical or micro-mechanical parts
- Precision assemblies
In these applications, the machine must be designed around:
- Controlled motion profiles
- Precision tooling
- Vision-guided inspection
- Specialized feeding solutions
What are the biggest risks in a custom automation project?
Common challenges include:
- Part feeding difficulties
- Changing product designs
- Long-lead components
- Unrealistic cycle time targets
Experienced machine builders address these risks by:
- Prototyping feeding solutions early
- Designing modular, upgradeable stations
- Building and testing the system with real parts before shipment
What makes SDC Automation different?
As a specialized custom automation machine builder and long-term custom automation partner, SDC focuses on high-speed, small-part automation.
These systems are commonly used for:
- Electrical device assembly
- Precision component assembly
- Automated test and inspection
- High-speed material handling
Why this specialization matters
Small-part, high-speed automation requires:
- Extremely precise motion control
- Advanced part feeding techniques
- Compact, rigid machine architectures
- Integrated inspection and testing
Companies like SDC that specialize in this niche are often able to achieve:
- Faster cycle times
- Higher repeatability
- More compact machine footprints
- Better long-term reliability
How do we get started with a custom automation project?
Most projects begin with a discovery phase where the machine builder evaluates:
- The current manual process
- Production requirements
- Quality targets
- Expected ROI
From there, the builder develops a concept and budget proposal.
Final thoughts: Is custom automation worth it?
For high-volume or precision manufacturing, custom automation is often one of the highest-ROI investments a company can make.
Across the industry, companies typically see:
- Significant labor reductions
- Higher quality and consistency
- Faster throughput
- Payback in one to two years
For manufacturers producing small, high-value parts at scale, custom automation is often the only way to meet modern cost, quality, and speed requirements. Whether implementing a single custom assembly machine or a multi-station automated production line, the long-term automation ROI often justifies the initial investment.
If you’re evaluating a custom machine, SDC can help you:
Schedule a Discovery Call with an Automation Engineer
- Analyze your process
- Estimate ROI
- Develop a practical automation roadmap
