Why comparing like-for-like automation systems matters
When investing in automation, it’s natural to focus on the headline number at the bottom of a quote. But automation systems are rarely simple, standardised products. They are complex solutions made up of many design choices, technologies, and assumptions. Two systems may appear similar on paper, yet perform very differently in reality.
This is why ensuring you are comparing like-for-like automation systems is not just good practice; it’s essential for protecting performance, reliability, and long-term value.
Automation is not one-size-fits-all
Unlike off-the-shelf equipment, automation systems are engineered solutions. There are countless ways to design a system to achieve the same high-level outcome, including differences in:
- Control architecture
- Hardware brands and specifications
- Software structure and functionality
- Levels of redundancy and fault tolerance
- Safety design and compliance
- Data handling, reporting, and integration
- Commissioning, testing, and documentation scope
Each of these variables can significantly affect cost, performance, and lifespan. If these details are not aligned when comparing quotes, the comparison becomes misleading.
The risk of comparing on price alone
A lower-priced automation quote can appear attractive, but without scrutiny, it may not represent the same solution at all. Common reasons prices differ include:
- Reduced functionality or simplified control logic
- Lower-grade or less robust hardware
- Minimal safety features or compliance assumptions
- Limited diagnostics, alarms, or data visibility
- Exclusion of future scalability or expansion capability
While these compromises may not be obvious during procurement, they often surface later as:
- Increased downtime
- Higher maintenance costs
- Reduced operational flexibility
- Additional variation costs
- Costly retrofit or upgrade projects
In many cases, the initial saving is quickly outweighed by long-term operational risk.
Key areas to align when reviewing quotes
To truly compare like for like, it’s important to look beyond the headline scope and ensure alignment in the following areas.
- Functional scope and performance
Do all systems:
- Perform the same control functions?
- Compatible with your whole SKU range
- Operate at the same speeds, tolerances, and capacities?
- Handle abnormal or fault conditions in the same way?
Small differences in functional scope can have a big impact on system usability and reliability.
- Hardware specification
Not all components are equal. Ensure consistency in:
- Hardware quality and functionality
- Vision systems
- Known use cases of specified hardware
- Power consumption and energy saving functions
Lower-spec hardware may function initially but struggle in demanding industrial environments.
- Software quality and structure
Software design is often invisible during quoting, yet critical to long-term success. Consider:
- Remove support tools
- Use of industry standards
- Ease of troubleshooting and modification
- Inclusion of diagnostics, alarms, and trending
A system with well-engineered software will be easier to maintain, adapt, and support over its lifetime.
- Safety and compliance
Safety systems can vary widely in design and rigor. Ensure quotes align on:
- Applicable UKCA/CE safety standards
- Safety integrity levels or performance levels
- Separation of safety and control systems
- Validation, verification, and documentation
Under-scoped safety designs can create serious operational and legal risks. This is becoming more of an issue with outside EU imported equipment.
- Testing, commissioning, and documentation
The level of testing included in a quote matters greatly. Confirm whether each proposal includes:
- Site acceptance testing (SAT)
- Simulation or dry testing
- Detailed on site Commissiong
- Complete electrical, software, and operational documentation
Cutting corners here often leads to longer commissioning times and unresolved issues after handover.
Considering the full lifecycle cost
Automation systems are long-term assets. A like-for-like comparison should consider not just capital cost, but total cost of ownership, including:
- Maintenance and support requirements
- Availability of spare parts
- Ease of future expansion or integration
- Vendor support capability and expertise
A well-designed system may cost more initially but deliver far greater value over its operational life.
Making better decisions
To ensure a fair and meaningful comparison:
- Develop a clear and detailed functional specification
- Ask suppliers to clearly state assumptions and exclusions
- Challenge differences in scope rather than accepting them at face value
- Evaluate technical compliance alongside commercial pricing
- Ask for site reference visits
By doing so, you move the conversation away from price alone and toward performance, reliability, and long-term success.
Conclusion
Automation is an investment in how your operation performs every day. With so many ways to design a system, it’s vital to ensure that quotes are truly comparable.
Comparing like for like doesn’t just lead to better purchasing decisions, it reduces risk, improves outcomes, and ensures you get the system you actually need, not just the one that looked cheapest on paper.
In automation, the details matter. Make sure when you’re comparing quotes and designs that you’re not comparing apples with oranges.
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