The decision to implement mobile robots in a company is often driven by high expectations of cost savings and productivity gains. But how realistic are these assumptions? In the second part of our five-part series, we focus on a crucial topic: Budget and Return on Investment (ROI) – and why it is essential to approach a robotics project with realistic expectations.
Why Budget and ROI Are Often Misjudged
Many companies enter a robotics project with a clear set of expectations:
✅ Robots will immediately reduce costs.
✅ ROI will be visible within a few months.
✅ Acquisition costs are the most significant expense.
However, the reality is often different:
🔹 Savings are typically realized over the long term, not immediately.
🔹 ROI depends heavily on process design.
🔹 Beyond acquisition, additional cost factors include integration, maintenance, and training.
Companies that address these aspects early on can avoid budget overruns and poor investments.
1. The True Cost Structure of Robotics Projects
A common misconception is that the investment in mobile robots is limited to acquisition costs. In reality, the budget consists of multiple components:
🔹 Hardware – Cost of robots, charging infrastructure, and accessories.
🔹 Software & Licenses – Fleet management, control software, and updates.
🔹 Integration – Adjustments to existing processes, IT interfaces, and employee training.
🔹 Maintenance & Support – Spare parts, software updates, and technical support.
💡 Tip: Instead of focusing solely on the purchase price, companies should create a Total Cost of Ownership (TCO) analysis to properly assess long-term costs.
2. How ROI is Really Calculated
Many companies expect their investment in mobile robots to pay off within just a few months. However, ROI depends on several factors:
✅ Direct Savings – Reduced manual transport, fewer errors.
✅ Productivity Gains – Faster processes, increased throughput.
✅ Flexibility & Scalability – Ability to adapt to growing order volumes.
✅ Bottleneck Reduction – Ensuring operational efficiency, especially in times of labor shortages.
💡 Tip: A realistic ROI timeframe for mobile robots is often between 1–3 years, depending on the industry, application, and existing processes.
3. Avoiding Hidden Costs – Where Companies Get Caught Off Guard
Even when major investments are well planned, unexpected costs often arise in early project phases:
❗ Process Adjustments – Existing workflows often need to be restructured for automation to be effective.
❗ Technical Integration – New interfaces for WMS, ERP, or other IT systems can be costly.
❗ Scaling – Expanding robot fleets incurs extra costs for charging infrastructure and additional software licenses.
💡 Tip: A cost-benefit analysis in the early stages helps avoid surprises and ensures realistic budgeting.
4. Planning the Budget: How Much Does a Robotics Project Really Cost?
Each project is unique, but a well-structured budget helps in making the right decisions. A typical breakdown might look like this:
| Cost Category | Typical Share of Total Budget |
|---|---|
| Hardware & Infrastructure | 40–50% |
| Software & Licenses | 10–20% |
| Integration & IT Adjustments | 15–25% |
| Training & Process Adjustments | 5–10% |
| Maintenance & Support | 5–10% |
💡 Tip: Understanding the cost structure early helps set priorities and make informed decisions about the project’s scope and scaling.
Conclusion: Setting Realistic Expectations for Budget and ROI
Mobile robotics can significantly boost efficiency – but only if companies have realistic expectations about costs, savings, and ROI.
🔹 Budget planning should include all relevant costs, not just acquisition.
🔹 ROI is often realized within 1–3 years, not immediately.
🔹 Hidden costs for integration, maintenance, and scaling must be accounted for.
What’s Next in This Series?
In our next post, we will explore how to choose the right technology and what factors play a key role in decision-making. Stay tuned!