Why do automation projects fail?

Article#: 00060

Date: 2021-04-30

Author: Radim

If we analyze a failed project, we can rarely identify a single cause of the problem.
Why do automation projects fail?

Project underestimation
If the estimate of the complexity of the project is made based on what appears at first glance or how much money the client can afford to pay.

Incorrect definition of a project
It is necessary to understand the customer's business and collect all the requirements.
It is necessary to communicate with users during development and show them unfinished versions of the application.

Insufficient analysis
Before we get to work, let's collect all the requirements and create a suitable concept.

Too much complexity of the project
If the requirements are exceeded, the project may become too complex.
One additional requirement usually doesn't spoil much, but if the project assignment is really too demanding, the result can become a low-performance monster.
Therefore, it is not such an art to do everything that users might ever need, but to select from that list those features that are really important, and only realize them.

Exaggerated emphasis on technology
One is often tempted to use the latest technical innovations in the project, even though he has no experience with it.
These innovations have not been adequately tested in practice and often unexpected problems appear, which would certainly not occur when using older but still suitable technologies.

Poor quality of the program code
Many problems, especially during the test, commissioning and maintenance phases, are caused by the poor quality of the program code.
This means that the code is too buggy, incomprehensible, or poorly commented.
Usually this happens when there is too much of a hurry and "no time" to write the code clearly, or when there are newcomers to the project who have not been well trained.
The end result of the project is largely what the programmer creates, and if it is not of adequate quality, it can completely devalue the functionality of the system.

Inappropriate methodologies, procedures, technologies
Once a development team applies a methodology or development process, all team members must understand it and not bypass them.
New methodologies must be introduced gradually.
The team members must not be forced to use the methodologies, but they have to get convinced of the benefits of the new methodologies.

Insufficient testing
Programmers are reluctant to test and usually underestimate testing.
Tests are also often shortened when a project gets into a time lag.
Customers and clients often underestimate the importance of test and pilot operations, so that many errors are only discovered when it is too late.

Bad project management
Project manager is responsible for ensuring that the project runs smoothly and that all problems are identified and resolved as quickly as possible.
Improper project management and poor coordination can cause a number of other problems, such as:

Team members have to wait for the result of the work of their colleagues.
The team members don't know what to do or they do what they want.
The result does not match the input.
And others.

Reference:

Petr Paleta. Computer Press (2003). Co programátory ve škole neučí.

© Radim-Automation, 2020–2025. All rights reserved.
Sharing of this article is permitted with proper attribution (link to the original page).

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Comment#: 00001

Date: 2021-06-07

User: Radim

"Keep your head in the clouds and your feet on the ground."
- Mike Robbins

Comment#: 00002

Date: 2021-06-19

User: Radim

"⇒ Make sure that you know the customer's needs and always keep an eye on them during the ongoing project.

⇒ Set realistic goals with regard to the scope, process and costs of the project.

⇒ Rely on proven methods and tools.

⇒ Put together a balanced team with clear hierarchies.

⇒ Delegate competencies, responsibilities and tasks clearly and make sure that everyone involved in the project has understood their mandate.

⇒ Track and communicate the progress of the project.

⇒ Write down important things, share your thoughts with others.

⇒ If something has not been tested, it will not work either.

⇒ Be adamant and proactively address potential problems.

⇒ Work according to the four-eyes principle."

Translated from:
- https://guteprojekte.ch/images/pdf/Checkliste_Stolpersteine_erkennen.pdf

Comment#: 00003

Date: 2021-06-19

User: Radim

"Rate the following statements on a scale of 1 (no agreement at all) to 5 (complete agreement).
Whenever possible, we ask you to add a comment to the statements. If you have the impression that a statement cannot be rated by you, please leave the field empty, but you can still make a comment.

Statements:

1. The project goals are clear.

2. I support the project goals.

3. In my opinion, the chosen procedure is promising.

4. The project organization meets the challenges.

5. All roles in the project are filled with the right people.

6. I can easily meet the expectations placed on me in the project.

7. I have enough time for the project.

8. The planning is current and realistic.

9. The mood in the project is good.

10. I get enough and good quality information about the project.

11. The tasks in the project are clear and comprehensible.

12. I assume that the project will be completed successfully.

13. Additional notes."

- https://guteprojekte.ch/images/guteprojekte_pdf/Checkliste_Standortbestetzung.pdf

Comment#: 00004

Date: 2021-06-23

User:

After all, three points are essential for the success of a project: communication, overview and coordination.

Comment#: 00005

Date: 2021-09-26

User: Radim

"How to ensure a project's failure:

1. Ignore the project environment (including stakeholders).

2. Push a new technology to market too quickly.

3. Don't bother building in fallback options.

4. When problems occur, shoot the one most visible.

5. Let new ideas starve to death from inertia.

6. Don't bother conducting feasibility studies.

7. Never admit a project is a failure.

8. Overmanage project managers and their teams.

9. Never, never conduct post-failure reviews.

10. Never bother to understand project tradeoffs.

11. Allow political expediency and infighting to dictate crucial project decisions.

12. Make sure the project is run by a weak leader."

- Jeffrey K. Pinto, Om P. Kharbanda. Business Horizons (1996). How to fail in project management (without really trying) (Page 46).

Comment#: 00006

Date: 2021-11-29

User: Radim

"1. Thoroughly plan your project before touching a keyboard

2. Write readable code because it’s read more than it’s written

3. Reduce the complexity of your programs to free mental capacity

4. Test and review every line of code in a program

5. Be an egoless programmer

6. Iterate on your designs and repeatedly measure progress"

- https://towardsdatascience.com/notes-on-software-construction-from-code-complete-8d2a8a959c69

Comment#: 00007

Date: 2022-09-13

User: Radim

"Writing good software requires a willingness to keep working at a problem, making code more readable, more efficient, and less error-prone over time by responding to feedback and thinking deeply about problems (sometimes the best tool is a pencil and paper for writing down your thoughts). Don’t expect to get things completely right the first time!"
- https://towardsdatascience.com/notes-on-software-construction-from-code-complete-8d2a8a959c69

Comment#: 00008

Date: 2022-10-01

User: Radim

"Everyone has a plan 'till they get punched in the mouth."
- Mike Tyson

Comment#: 00009

Date: 2022-10-30

User: Radim

"Process automation projects are difficult to manage. The inherent complexity, evolving scope, schedule constraints, and human interaction all contribute unique challenges. Utilizing a project manager and a team with experience managing these characteristics and the ability to maintain proper execution discipline are critical to achieving success."
- https://blog.isa.org/industrial-automation-projects-challenging-management

Comment#: 00010

Date: 2022-10-31

User: Radim

"Disciplined testing and commissioning procedures executed by qualified resources are critical for safe and efficient startup. Shortcuts here inevitably lead to ongoing operational problems, costing many times the minimal savings from reduced commissioning time."
- https://blog.isa.org/industrial-automation-projects-challenging-management

Comment#: 00011

Date: 2022-11-16

User: Radim

"The later in the development cycle we discover a bug in the software, the more expensive it is to fix."
- https://www.linkedin.com/pulse/unit-testing-world-industrial-automation-jakob-sagatowski/?trackingId=8Il2af6t8cNMxCT2pRn76Q%3D%3D

Comment#: 00012

Date: 2022-11-30

User: Radim

New problems occur in real operation that were not expected or experienced during development or test operation.
Then you are happy if you know the system / devices well, if you know how they work, how they are connected and controlled, etc. This know-how comes simply from working on the system, from solving smaller and larger problems...

Comment#: 00013

Date: 2022-11-30

User: Radim

During development, do not use other (preliminary) hardware than the one selected for production. You gain important experience with the hardware. You will find out whether the performance is sufficient and learn how to eliminate problems that arise during development. If the software development phase is carried out on the hardware designed for sharp operation, you will experience fewer unpleasant surprises after the machine is commissioned.

Comment#: 00014

Date: 2022-12-12

User: Radim

It's easy to give advice at the beginning of a project. Everyone here knows best. But are these consultants able to bear the consequences of a failed development that lasts for years and cannot reach satisfaction?

It is usually experienced people who are not asked for their opinion when a concept is being defined, but who repeatedly have to struggle with the consequences of wrong decisions, workarounds and fixes due to the fact that conceptual decisions were not made based on experience.

⇒ Involve experienced people in conceptual decisions and thus avoid later problems.
⇒ Hold people accountable for their decisions and actions!

Comment#: 00015

Date: 2022-12-15

User: Radim

"The entire development cycle should be structured in such a way that communication with the customer is as frequent as possible, which is ultimately more important for the success of the project than the technology used."
Translated from:
- Petr Paleta. Computer Press (2003). Co programátory ve škole neučí (Page 255).

Comment#: 00016

Date: 2022-12-26

User: Radim

"A logical exercise in which project managers must engage is to continually ask a series of "What if?" questions. This forces the project manager and the team to search out likely problem areas actively rather than wait for trouble to find them.
An important side note: Research has demonstrated that the project managers who spend adequate up-front time developing a series of "What if?" scenarios and their responses to them are more successful than those who operate in a purely reactive manner, waiting until problems occur before weighing their various responses."
- Jeffrey K. Pinto, Om P. Kharbanda. Business Horizons (1996). How to fail in project management (without really trying) (Page 48).

Comment#: 00017

Date: 2023-03-08

User: Radim

Do you know what AI means? Yes, AI means Artificial Intelligence...
And do you know what AE means? Well, AE means Artificial Engagement. You can observe AE in organizations where the shared vision is not clear and where leadership is not concerned with driving the vision into reality. In the organization with AE everyone is somehow busy, but it doesn't help on the way to the realistic goal (to realizing the vision).

Comment#: 00018

Date: 2023-06-08

User: Radim

"Today, technical debt, also known as tech debt and code debt, usually occurs when development teams choose to write speedy code while building new features of a software development product. Speedy code delivery can help your team meet deadlines, and the debt you accrue may be worth it, though it could also lead to negative outcomes if managed incorrectly. These negative outcomes aren’t always avoidable once the decision to accrue technical debt has been made."
- https://asana.com/resources/technical-debt

Comment#: 00020

Date: 2023-07-14

User: Radim

"A good interface is easy to learn, leads to faster reaction time, safer operations and higher productivity. You deserve a system that is intuitive - one that at a glance you can see what actions need to be taken and is easy to navigate."
- General Electric (2021). Modern HMI/SCADA Guidebook for Efficient Operations.
- https://www.ge.com/digital/lp/modern-hmiscada-guidebook-efficient-operations

Comment#: 00021

Date: 2023-08-11

User: Radim

"How to eliminate fifty percent of your business worries.

Everyone who wishes to present a problem to me must first prepare and submit a memorandum answering these four questions:
1. What is the problem?
2. What is the cause of the problem?
3. What are all the possible solutions of the problem?
4. What solution do you suggest?

My associates rarely come to me now with their problems. Why? Because they've discovered that in order to answer those four questions, they have to get all the facts and think their problems through. And they've done that, they find in three-fourths of the the cases they don't have to consult me at all because the proper solution has popped out like a piece o fbread popping up from an electric toaster. Even in those cases where consultation is snecessary the discussion takes about one-third of the time formely required because it proceeds along an orderly, logical path to a reason conclusion."

- Dale Carnegie. Crescent News (1944). How to Stop Worrying and Start Living.
- https://www.youtube.com/watch?v=fKzlc_N2yxw (01:07:50 - 01:09:53)

Comment#: 00022

Date: 2023-08-11

User: Radim

"Basic techniques in analysing worry:
Rule 1 - get the fact. Half the worry in the wold is caused by people trying to make decisions before they have sufficient knowledge on which to base a decision.
Rule 2 - after carefully weighing all the facts come to a decision.
Rule 3 - once a decision is carefully reached, act, get busy carrying out your decision and dismiss all enxiety about the outcome.
Rule 4 - when you or any of your associates are tempted to worry about a problem, write out and anser the following questions:
a) What is the problem?
b) What is the cause of the problem?
c) What are all possible solutions?
d) What is the best solution?"

- Dale Carnegie. Crescent News (1944). How to Stop Worrying and Start Living.
- https://www.youtube.com/watch?v=fKzlc_N2yxw (01:12:50 - 01:13:50)

Comment#: 00024

Date: 2023-08-17

User: Radim

Why is there never enough time to do it right the first time, but always enough time to do it over?

"The saying "There's never enough time to do it right the first time, but always enough time to do it over" reflects a common observation about human behavior and project management. It suggests that people often rush through tasks or projects initially, hoping to save time and effort, but end up making mistakes or producing subpar results. As a result, they eventually need to invest more time and resources to fix those mistakes or redo the work properly.

There are several reasons why this phenomenon occurs:

1. Underestimation of Complexity: People might underestimate the complexity or difficulty of a task or project at the outset. This can lead to inadequate planning and allocation of resources, resulting in mistakes or oversights.

2. Pressure to Meet Deadlines: There is often pressure to complete tasks or projects quickly to meet deadlines. This can lead to shortcuts being taken or important steps being skipped in the interest of saving time.

3. Lack of Attention to Detail: When rushing through a task, individuals might not pay enough attention to details, leading to errors that require corrections later.

4. Overconfidence: Sometimes, people might overestimate their abilities or knowledge, leading them to believe they can complete a task quickly without proper preparation or diligence.

5. Incomplete Information: In some cases, tasks or projects might be started without having all the necessary information or requirements. This can lead to incorrect assumptions and decisions.

6. Limited Resources: Constraints on resources such as time, money, or manpower might force people to cut corners initially, with the intention of fixing things later when more resources are available.

7. Learning Curve: Sometimes, tasks involve new skills or technologies that individuals need to learn along the way. Initial attempts might be suboptimal as people are still acquiring the necessary expertise.

The saying serves as a reminder that investing the necessary time and effort upfront to do a task properly can save more time and resources in the long run. Proper planning, attention to detail, and thorough execution can help prevent mistakes and the need for redoing work.

However, it's worth noting that the saying is not universally true. In some cases, rushing through tasks might yield acceptable results, and redoing work might not be necessary. It all depends on the nature of the task, the level of expertise involved, and the specific circumstances."

- https://chat.openai.com (Why is there never enough time to do it right the first time, but always enough time to do it over?)

Comment#: 00025

Date: 2023-08-18

User: Radim

"Don't dig deep into anything because it costs us money. Just pretend that we are experts and hope that the others gets the chestnuts out of the fire."
- unnamed user (own experiences leading to this ironic statement)

Comment#: 00027

Date: 2023-09-11

User: Radim

Does it make sense to think about digitalization if we don't see any use case?

"If you don't see any practical use case or clear benefit for digitalization in your specific situation, it may not make sense to pursue it blindly. Digitalization should always align with your organization's goals and needs. Here are some considerations:

1. Assess Business Objectives: Start by identifying your organization's objectives and challenges. Digitalization should align with your strategic goals, whether it's improving efficiency, reaching new markets, enhancing customer experiences, or reducing costs.

2. Customer Demands: Consider whether your customers or clients expect or would benefit from digital solutions. If there's no demand for digital services, investing in them may not provide a return on investment.

3. Competitive Landscape: Analyze your competition. If your competitors are effectively utilizing digital technologies to gain a competitive advantage, it might be necessary to explore digitalization to stay relevant.

4. Cost-Benefit Analysis: Conduct a thorough cost-benefit analysis to determine if the potential benefits of digitalization outweigh the costs. If the investment doesn't offer a reasonable return, it might not be justified.

5. Resource Availability: Evaluate whether you have the necessary resources, including financial resources, technical expertise, and staff training, to implement and sustain digital solutions effectively.

6. Future Growth: Consider the scalability of your organization. Even if you don't currently see a clear use case for digitalization, it's essential to think about your organization's future growth and whether digital technologies could play a role in that growth.

7. Technology Trends: Stay informed about industry trends and emerging technologies. While there may not be an immediate use case, technological advancements could create new opportunities down the line.

8. Customer Feedback: Engage with your customers or stakeholders to gather feedback on their needs and preferences. They may provide insights that could uncover potential use cases for digitalization.

9. Pilot Projects: Instead of a full-scale digital transformation, consider starting with smaller pilot projects to test the waters and assess the feasibility and impact of digital solutions in a controlled environment.

10. Consult Experts: Seek advice from digital transformation consultants or experts in your industry. They can provide insights into potential use cases and help you determine if digitalization is appropriate for your organization.

In some cases, it may indeed be the case that digitalization doesn't make sense for your organization at a given time. However, it's essential to regularly revisit this assessment as technology and business landscapes evolve. What might not be relevant today could become essential in the future. Ultimately, the decision to pursue digitalization should be guided by a thorough understanding of your organization's unique needs and circumstances."

- https://chat.openai.com (Does it make sense to think about digitalization if we don't see any use case?)

Comment#: 00028

Date: 2023-09-15

User: Radim

Complaints and identified problems are good sources of innovation.

Comment#: 00029

Date: 2023-09-27

User: Radim

"By continuously improving the design of code, we make it easier and easier to work with.
This is in sharp contrast to what typically happens: little refactoring and a great deal of attention paid to expediently add new features.
If you get into the hygienic habit of refactoring continuously, you'll find that it is easier to extend and maintain code."

- Joshua Kerievsky. Addison-Wesley (2004). Refactoring to Patterns.

Comment#: 00030

Date: 2023-10-02

User: Radim

How to get the right intuition?

"Developing and honing your intuition can be a valuable skill, but it's important to remember that intuition is inherently subjective and can't always be "right" in an objective sense. However, you can work on improving the accuracy and reliability of your intuition by following these tips:

1. Increase Your Knowledge and Experience: The more you know about a particular subject or domain, the better your intuition is likely to be within that area. Gain expertise and experience through study, practice, and exposure.

2. Trust Your Gut: Pay attention to your gut feelings or initial impressions. Sometimes, your subconscious mind processes information faster than your conscious mind, leading to intuitive insights. Don't dismiss these feelings outright; give them consideration.

3. Practice Mindfulness: Mindfulness meditation can help you become more aware of your thoughts and feelings. This self-awareness can improve your ability to recognize and trust your intuition.

4. Keep a Journal: Maintain a journal where you record your intuitive hunches and the outcomes. Over time, this can help you assess the accuracy of your intuition and learn from your experiences.

5. Seek Feedback: Discuss your intuitive insights with trusted friends, mentors, or colleagues. They can provide valuable perspectives and help you refine your intuition by offering feedback on your decisions.

6. Validate with Data: When possible, seek out data or information that can confirm or refute your intuitive impressions. This can help you develop a more evidence-based form of intuition.

7. Relax and Clear Your Mind: High-stress levels or a cluttered mind can cloud your intuition. Engage in relaxation techniques like deep breathing, meditation, or progressive muscle relaxation to clear your mind and enhance your intuitive abilities.

8. Ask Open-Ended Questions: When facing a problem or decision, ask yourself open-ended questions and let your mind wander. This can stimulate creative and intuitive thinking.

9. Learn from Mistakes: Embrace your intuition's imperfections. When your intuition leads you astray, use those experiences as learning opportunities. Analyze what went wrong and adjust your intuition accordingly.

10. Practice Patience: Sometimes, intuition needs time to develop. Don't rush your decision-making process if you're unsure. Give yourself the space to allow your intuition to emerge.

11. Combine with Analysis: Balance your intuition with analytical thinking. For important decisions, use your intuition as an initial guide but then follow up with critical analysis and data-driven assessment.

12. Cultivate Emotional Intelligence: Understand and manage your emotions effectively. Emotional intelligence can enhance your ability to perceive and interpret your own and others' emotional signals, which can inform your intuition.

Remember that intuition can vary from person to person, and it's not always infallible. It's a skill that you can refine over time, but it's also important to recognize its limitations and use it as a complementary tool alongside rational thinking and evidence-based decision-making when appropriate."

- https://chat.openai.com (How to get the right intuition?)

Comment#: 00031

Date: 2023-10-04

User: Radim

"Never discourage anyone who continually makes progress, no matter how slow."
- Plato

Comment#: 00033

Date: 2023-11-28

User: Radim

If you choose the path to the left at the crossroads, you will not be able to pick the fruit that grows on the path to the right.
So collect all the requirements and decide which ones you want to choose and which ones you want to eliminate by weighing up the pros and cons.

Comment#: 00034

Date: 2024-01-05

User: Radim

I have found the solution !!!
But unfortunately the problem did not match my solution.
:-)

Comment#: 00035

Date: 2024-04-10

User: Radim

"Code conventions are important to programmers for a number of reasons:

• 40%–80% of the lifetime cost of a piece of software goes to maintenance.

• Hardly any software is maintained for its whole life by the original author.

• Code conventions improve the readability of the software, allowing engineers to understand new code more quickly and thoroughly.

• If you ship your source code as a product, you need to make sure it is as well packaged and clean as any other product you create."

- https://en.wikipedia.org/wiki/Coding_conventions

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