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Flevy Management Insights Case Study
Robotic Process Automation in Metals Industry for Efficiency Gains


There are countless scenarios that require Robotic Process Automation. Fortune 500 companies typically bring on global consulting firms, like McKinsey, BCG, Bain, Deloitte, and Accenture, or boutique consulting firms specializing in Robotic Process Automation to thoroughly analyze their unique business challenges and competitive situations. These firms provide strategic recommendations based on consulting frameworks, subject matter expertise, benchmark data, best practices, and other tools developed from past client work. Let us analyze the following scenario.

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Consider this scenario: The organization, a prominent player in the metals industry, is grappling with the challenge of scaling their Robotic Process Automation (RPA) initiatives.

Having invested in RPA to streamline operations and reduce manual errors, they have not achieved the anticipated efficiency gains. The company has seen its market share grow, yet its operational costs have surged disproportionately, suggesting that their RPA deployment is not optimized for their complex, multi-faceted processes.



Upon reviewing the situation, it seems that there could be several underlying causes for the RPA inefficiencies. The first hypothesis might be that the RPA bots were not accurately or comprehensively mapped to the organization’s processes, leading to suboptimal automation. A second possibility could be that the organization's RPA governance and maintenance protocols are inadequate, causing frequent disruptions. Lastly, the organization's workforce might not be adequately trained to manage and work alongside the RPA solutions, creating bottlenecks instead of improving flow.

Strategic Analysis and Execution Methodology

The organization can navigate through its RPA challenges by adopting a structured 4-phase methodology, which is designed to maximize efficiency and align RPA initiatives with business goals. This proven process, often followed by leading consulting firms, ensures a thorough understanding of the current state, identifies improvement areas, and implements solutions effectively.

  1. Assessment and Process Selection: Identify processes that are suitable for RPA by analyzing their complexity, frequency, and rules-based nature. Key questions include: What are the current performance metrics? Where are the bottlenecks? What is the impact of automation on these processes?
    • Review existing RPA deployments; assess alignment with business objectives.
    • Analyze process documentation and conduct stakeholder interviews.
    • Deliver an assessment report highlighting potential RPA candidates.
  2. RPA Strategy and Roadmap Development: Craft a tailored RPA strategy that aligns with the organization’s Strategic Planning and Digital Transformation goals. The strategy should define the governance model, scale of automation, and a roadmap for implementation.
    • Establish RPA governance, including roles and responsibilities.
    • Develop a prioritization matrix for RPA implementation.
    • Prepare a detailed RPA implementation roadmap.
  3. Bot Development and Testing: Develop RPA bots using best practices for coding and configuration. Conduct thorough testing to ensure bots perform as expected under various scenarios.
    • Engage in agile bot development with iterative feedback loops.
    • Perform rigorous testing, including user acceptance testing.
    • Issue an interim report on bot performance against KPIs.
  4. Monitoring, Scaling, and Continuous Improvement: After deployment, continuously monitor bot performance to ensure they are delivering the expected benefits. Identify opportunities for scaling and improving RPA initiatives.
    • Implement a performance management system for RPA.
    • Scale RPA solutions across the organization, based on results and feedback.
    • Deliver a final report on RPA performance and future recommendations.

Learn more about Digital Transformation Strategic Planning Performance Management

For effective implementation, take a look at these Robotic Process Automation best practices:

Digital Transformation: Artificial Intelligence (AI) Strategy (27-slide PowerPoint deck)
Process Automation & Digitalization Assessment (41-slide PowerPoint deck)
Robotic Process Automation (RPA) (36-slide PowerPoint deck)
Process Automation Toolkit (321-slide PowerPoint deck)
Robotic Process Automation (RPA) - Implementation Toolkit (Excel workbook and supporting ZIP)
View additional Robotic Process Automation best practices

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Robotic Process Automation Implementation Challenges & Considerations

One key concern might be the integration of RPA with existing legacy systems and the ability to maintain bot performance over time. Another consideration is the change management aspect, ensuring that employees are prepared and supportive of the RPA deployment. Lastly, executives often question the scalability of RPA solutions and their ability to deliver consistent results across diverse business units.

Expected business outcomes include a 30-50% reduction in process cycle times, a significant decrease in manual errors, and an overall operational cost reduction by up to 40%. It is also anticipated that employee satisfaction will improve due to the elimination of repetitive tasks, freeing them for more value-added work.

Implementation challenges include aligning RPA initiatives with business strategy, managing change resistance among staff, and ensuring continuous improvement beyond initial deployment.

Learn more about Change Management Continuous Improvement Cost Reduction

Robotic Process Automation KPIs

KPIS are crucial throughout the implementation process. They provide quantifiable checkpoints to validate the alignment of operational activities with our strategic goals, ensuring that execution is not just activity-driven, but results-oriented. Further, these KPIs act as early indicators of progress or deviation, enabling agile decision-making and course correction if needed.


What gets measured gets managed.
     – Peter Drucker

  • Process Cycle Time: Measures the time taken to complete a process before and after RPA implementation.
  • Error Rate: Monitors the number of errors in a process, aiming for a significant reduction post-RPA.
  • Cost Savings: Tracks the operational cost savings achieved through RPA deployment.
  • Employee Productivity: Assesses the impact of RPA on employee productivity and time allocation.

For more KPIs, take a look at the Flevy KPI Library, one of the most comprehensive databases of KPIs available. Having a centralized library of KPIs saves you significant time and effort in researching and developing metrics, allowing you to focus more on analysis, implementation of strategies, and other more value-added activities.

Learn more about Flevy KPI Library KPI Management Performance Management Balanced Scorecard

Implementation Insights

Insights gained from the implementation process reveal that successful RPA initiatives require a strong alignment with the company’s strategic objectives and comprehensive change management to ensure staff buy-in. Also, iterative development and continuous feedback loops are critical to refine bot performance and meet business needs effectively.

According to Deloitte's Global RPA Survey, 78% of organizations that have implemented RPA expect to significantly increase investment in RPA over the next three years, underlining the strategic importance of getting RPA right from the outset.

Robotic Process Automation Deliverables

  • Operational Assessment Report (PowerPoint)
  • RPA Strategy and Governance Framework (Word)
  • RPA Implementation Roadmap (PowerPoint)
  • Bot Performance Analysis (Excel)
  • RPA Scaling Plan (PowerPoint)

Explore more Robotic Process Automation deliverables

Robotic Process Automation Best Practices

To improve the effectiveness of implementation, we can leverage best practice documents in Robotic Process Automation. These resources below were developed by management consulting firms and Robotic Process Automation subject matter experts.

Robotic Process Automation Case Studies

A Fortune 500 metals company implemented RPA in their accounts payable department and saw a 60% reduction in invoice processing time. Another case study involves a global mining firm that automated their procurement process, resulting in a 45% decrease in procurement cycle time and a 30% cost saving.

Explore additional related case studies

Alignment with Overall Business Strategy

Ensuring that RPA initiatives are in sync with the broader business strategy is paramount. RPA should not be viewed as a standalone project but as an integral part of the organization's digital transformation efforts. This means that RPA's objectives should directly contribute to achieving strategic business goals, such as enhancing customer experience, driving growth, or improving agility.

According to McKinsey, companies that have successfully scaled RPA report that having a clear vision of how automation fits into the broader picture was critical. This includes ensuring that RPA efforts are coordinated with other automation and AI initiatives, to avoid duplication of efforts and to leverage synergies between technologies.

Learn more about Customer Experience

Change Management and Workforce Transition

When implementing RPA, the human element cannot be overlooked. Effective change management practices are essential not only for ensuring a smooth transition but also for harnessing the full potential of RPA. Employees need to understand the benefits of RPA, how it will impact their roles, and the new opportunities it presents for more strategic and creative work.

Research from Gartner indicates that one of the main reasons for the failure of RPA projects is resistance from employees. To counter this, companies should invest in training programs to upskill their workforce and create a culture of continuous learning and innovation. Moreover, involving employees in the RPA development process can lead to better-designed bots and higher adoption rates.

Scalability and Performance Consistency

Scalability is a critical consideration for executives contemplating RPA investments. As the business grows and evolves, so too must the RPA solutions. For RPA to be truly successful, it must demonstrate the ability to scale across different functions and geographies without significant drops in performance.

Bain & Company emphasizes the importance of building an RPA center of excellence (CoE) as a key factor in scaling RPA. The CoE serves as a hub of expertise and best practices, ensuring that RPA deployments are consistent and aligned with business goals. It also helps in addressing the varying needs of different business units, customizing RPA solutions to meet those specific requirements.

Learn more about Best Practices Center of Excellence

Measuring the Impact of RPA on Business Outcomes

It is crucial for executives to understand how the success of RPA initiatives is measured. While KPIs such as cost savings and error reduction are important, they only tell part of the story. To truly gauge the impact of RPA, it's necessary to measure outcomes like customer satisfaction, employee engagement, and speed to market.

Accenture's research suggests that leading organizations measure the success of their RPA programs through a balanced scorecard approach, looking at a range of financial and non-financial metrics. This provides a holistic view of RPA's impact and helps in making informed decisions about future investments in the technology.

Learn more about Balanced Scorecard Employee Engagement Customer Satisfaction

Additional Resources Relevant to Robotic Process Automation

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Key Findings and Results

Here is a summary of the key results of this case study:

  • Reduced process cycle times by 45% across key operational processes, exceeding the initial target range of 30-50%.
  • Achieved a 40% reduction in operational costs, aligning with the anticipated cost savings outlined in the strategic goals.
  • Significantly decreased manual errors by 60%, surpassing the error reduction KPI and enhancing overall process quality.
  • Increased employee productivity and satisfaction by reallocating staff from repetitive tasks to more strategic roles, though specific quantification is not provided.
  • Successfully scaled RPA solutions across multiple business units, demonstrating the ability to adapt and perform consistently.
  • Established a comprehensive RPA governance framework, ensuring alignment with the organization's strategic planning and digital transformation goals.

The initiative is considered a success, evidenced by the significant reduction in process cycle times and operational costs, and the substantial decrease in manual errors. These results directly contribute to the organization's strategic objectives of enhancing efficiency and productivity. The successful scaling of RPA solutions across different business units further underscores the initiative's success, demonstrating effective scalability and performance consistency. However, the lack of specific quantification in increased employee productivity and satisfaction suggests an area for improvement. Alternative strategies, such as more focused employee engagement and feedback mechanisms, could have potentially enhanced these outcomes.

For next steps, it is recommended to focus on continuous improvement and optimization of existing RPA deployments, leveraging the established governance framework. Additionally, exploring advanced analytics and AI integration with RPA could unlock further efficiencies and capabilities. Investing in targeted training programs to further enhance employee skills and engagement with RPA technology will also be crucial for sustaining momentum and fostering an innovative, continuous improvement culture.

Source: Robotic Process Automation in Metals Industry for Efficiency Gains, Flevy Management Insights, 2024

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