The Most Common Challenges in AI and Automation Implementation
The decision took about ninety seconds. A delivery team was scoping an automation over an order-entry workflow, and someone asked whether they needed to profile the source data before building. The answer was no, because the field list was already in the requirements document and the requirements document had been signed off. Everyone moved on. The requirements document had been written from the customer relationship management screen. The screen showed a clean, single-value country field. The table behind it held three years of free-text entries, because a form validation rule had been added in the second year and nobody had gone back to fix what came before. The automation was built, tested against recent records, piloted against recent records, and went live. It failed on a fifth of the historic backlog, which is where the volume was. Nothing about that failure was unknowable in week one. It was findable with about a day of profiling. It got found in week nine instead, by which time the fix was not a day of profiling but a rebuild of the parsing logic, a re-run of everything already processed, and a conversation with a sponsor who had stopped asking about progress and started asking about the plan. That gap is the actual subject of this article. The challenges below are the ones that come up on nearly every AI and automation programme, and most lists cover them. What most lists leave out is that each challenge has a stage where it is cheap to find and a stage where it is expensive, and the difference is not a rounding error. So rather than walking the challenges in order, this piece sorts them by where they are findable, prices the ladder, and then says what you can buy that moves a problem down it. First, a working definition Intelligent automation is not a product. It is a workflow, a set of connections between systems, and artificial intelligence applied at the points where the inputs are not predictable. Robotic process automation, usually shortened to RPA, is the part that drives existing screens and applications when there is no application programming interface, or API, available to call instead. AI is the part that copes with email text, documents, and free-form requests. If you want the longer version of that distinction, we have written it up separately. Definitions matter here only because they set the boundary of what can go wrong. A workflow can be wrong. A connection can be wrong. A model can be wrong. And all three can be wrong in ways that a demonstration will not show you. Five places a problem can be found, and what each one costs Take one material defect. Not a typo, not a cosmetic issue, but something that means the automation produces a wrong or unusable result on a real class of input. Here is what clearing that single defect costs at each of five detection points, at a blended delivery rate of EUR 85 per hour. Found in discovery or design, before anything is built: about 2 hours, so EUR 170. You change a diagram and a decision. Found during build: about 6 hours, EUR 510. You change code that exists but has no dependents yet. Found in user acceptance testing: about 14 hours, EUR 1,190. You change code, re-run the test cycle, and update the test evidence. Found in a pilot: about 30 hours, EUR 2,550. Add a regression pass, a change record, and a re-brief for the pilot group. Found live, at full volume: about 70 hours, EUR 5,950. Add impact analysis, an emergency change window, and a fix that has to work first time. The live figure carries a second cost that the earlier ones do not. By the time a full-volume defect is visible, work has already been processed wrongly. Assume 40 items at 12 minutes each to identify and correct, at a business-side rate of EUR 40 per hour. That is 8 hours and EUR 320, which takes the true cost of one late defect to EUR 6,270, against EUR 170 for the same defect caught in discovery. There is a harder version of the live case. On one engagement for a Nordic healthcare provider, the workflow could not be taken offline to be corrected, because the service it fed had no acceptable downtime window. The correction had to be designed, built, and deployed while the automation kept running, with a rollback path proven before anything was applied. Nothing about the underlying defect was unusual. The constraint on when it could be fixed is what made it expensive. A worked model: the same twelve defects, found in two different places This model is illustrative. The rates and hours are plausible mid-market figures, not measurements from a specific client, and the point of publishing the arithmetic is that you can substitute your own numbers and see whether the conclusion survives. It is built to make one comparison only, and it deliberately holds the thing most business cases quietly change. The programme has twelve material defects. Both versions have all twelve. No readiness activity removes a defect from existence. It only moves the rung at which the defect is found. That constraint is what makes this different from a savings case, because there is no productivity assumption anywhere in it. Where the twelve surfaced Version one, thin discovery and no pilot. Two workshops, the requirements document, straight into build, one round of user acceptance testing on recent data, go live. Discovery: 1 defect Build: 2 defects User acceptance testing: 3 defects Pilot: 2 defects Live at full volume: 4 defects Version two, readiness first. Process discovery run against the actual work rather than the described work, a data profiling pass over the full history rather than the recent slice, and a pilot restricted to one variant of the workflow so that failures are legible. Discovery: 5 defects Build: 3 defects User acceptance testing: 2 defects Pilot: 1 defect Live at full volume: 1




