Field tests · Field notes
A robot pilot needs a cost per accepted unit
An illustrative calculation that includes supervision, setup, rework, and the work the robot leaves behind.
Use a small, inspectable unit
Pick a completed output that matters to the next trade: an accepted layout point, installed component, or inspected asset. Define its acceptance criteria before the trial. This is a proposed evaluation method, not a claim about any vendor’s economics. The purpose is to make a failed or mediocre trial as easy to interpret as a good one.
An example with deliberately ordinary numbers
Suppose a manual process costs $1,200 and delivers 400 accepted units: $3 per unit. A robot trial costs $700 in equipment allocation, $300 in operator time, $200 in setup, and $100 in rework. Its $1,300 total over 500 accepted units is $2.60 per unit. These numbers are invented for the example. They imply a $0.40 difference per accepted unit, not a guaranteed saving.
Change one assumption
If only 350 units pass inspection, the same $1,300 becomes about $3.71 per accepted unit. The comparison reverses. This is why an output acceptance rule matters more than an impressive gross production count. Keep training, travel, charging, supervision, insurance, and mobilization visible where they apply; do not force every cost into a convenient hourly rental rate.
Avoid scaling the best hour
A short pilot may miss breakdowns, weather delays, layout changes, or service visits. Separate the observed result from an annual scenario. For the scenario, state the assumed utilization and downtime, then calculate a lower-utilization case. If the decision depends on near-perfect use, that is a condition to investigate before committing.
Sources & scope
Prepared October 13, 2026 with AI assistance. Vendor descriptions are attributed claims. Worksheets are proposed methods; numerical examples are illustrative. No hands-on vendor testing is represented.