Manual processes are the hidden tax on manufacturing productivity. Every time an employee copies data between systems, manually routes an approval, or hand-types information from one document to another, time is wasted, errors are introduced, and skilled workers are diverted from higher-value activities. Workflow automation eliminates these bottlenecks, enabling manufacturers to do more with existing resources while improving accuracy and consistency. By 2026, it is predicted that 30% of enterprise companies will have automated at least half their network activities.
The Power of Automation in Manufacturing
The global RPA market is growing from $35.27 billion in 2026 to an estimated $247.34 billion by 2035, driven by the proven returns organizations achieve from automating repetitive tasks. For manufacturers, automation delivers predictable outcomes, lower operational costs, and the ability to scale processes to meet seasonal demand increases or growth targets with confidence.
Key Automation Opportunities
Order Processing and Fulfillment
Automating the flow from purchase order receipt through production scheduling to shipping notification eliminates manual handoffs, reduces order processing time, and ensures nothing falls through the cracks. Automated workflows can validate orders against inventory, trigger production schedules, and generate shipping documents without human intervention.
Invoice and Payment Processing
Accounts payable automation matches invoices to purchase orders and receiving records, routes exceptions for review, and processes payments on schedule. This reduces processing costs, captures early payment discounts, and frees finance staff from repetitive data entry.
Quality and Compliance Workflows
Automated quality workflows route inspection results to the right reviewers, trigger corrective action requests when defects are detected, and maintain audit trails that satisfy regulatory requirements. These workflows ensure consistency in quality processes regardless of staffing changes or workload fluctuations.
Inventory and Supply Chain Automation
Automated reorder triggers, supplier communication workflows, and inventory reconciliation processes keep materials flowing without manual monitoring. When inventory drops below defined thresholds, automated workflows can generate purchase requisitions, send RFQs to approved suppliers, and update expected delivery dates in the ERP.
Employee Onboarding and HR Processes
Manufacturing companies with shift-based workforces benefit from automated onboarding workflows that provision system access, schedule training, assign safety certifications, and track completion without manual coordination between HR, IT, and department managers.
Microsoft Power Automate: The Platform of Choice
For manufacturers in the Microsoft ecosystem, Power Automate provides both cloud-based workflow automation and desktop RPA within a single platform. Its low-code, drag-and-drop interface enables non-technical users to build automations, while its AI Builder capabilities add intelligence through object detection, document processing, and predictive analysis. Power Automate connects natively to Microsoft 365, Dynamics, SharePoint, and hundreds of third-party services, making it an ideal automation platform for manufacturing environments.
The Synesis Approach
Synesis International identifies and automates the manual workflows that consume the most time and create the most errors in your manufacturing operation. We use Microsoft Power Automate and custom development to create automation solutions that integrate with your existing systems, including SAP Business One, Microsoft 365, and legacy applications. Our goal is to free your team from repetitive tasks so they can focus on the work that drives your business forward.