17 Common Challenges of Business Process Automation (+ Fixes That Work)

17 Common Challenges of Business Process Automation (+ Fixes That Work)

When businesses decide to automate, they often expect smooth sailing. They envision quick wins that will save time and money. However, the reality is that business process automation can come with its own set of challenges. A big one? Rushing into automation without fully understanding the common pitfalls. This article will explore the challenges of business process automation to help you achieve your goals. With a clear understanding of Artificial Intelligence Operating System and what to expect, you can implement proven solutions that will save you time, reduce errors, and improve efficiency.

AI Acquisition's AI operating system can help you tackle the challenges of business process automation head-on and achieve your objectives. It does this by providing a clear road map with prebuilt solutions and workflows to help you get started and guide your automation journey.

What Problems Does Business Process Automation Solve?

Person Working -  Challenges of Business Process Automation

One of the biggest advantages of business process automation is that it can help consolidate all the processes within your company and transform them into one overarching solution. Most businesses have a complex environment consisting of numerous disparate applications. 

Managing Complexity Across Legacy, On-Premise, and Cloud Applications

As your organization grows in size and new technologies are adopted, the complexity increases as well. With business process automation, you can use point-to-point integration to make all the applications work together seamlessly. 

Of course, the more processes you have, the more time you need to spend integrating them. With the right business process automation tool, you can automate the entire integration process, whether you have legacy systems, on-premise apps, or cloud-based solutions.

Finding and Rectifying Manual Errors

With numerous applications and a high volume of data, the room for manual human errors is also bigger. Human errors can be made while manually entering data or sharing files, and the cost of correcting these can be incredibly high for your business. 

Business process automation can solve this problem by automating manual data entry tasks, which in turn leads to higher productivity and eliminates manual errors. A BPM tool can enable such automation seamlessly.

Time-Consuming Manual Reporting

To make sure your enterprise is running smoothly and you can make informed business decisions, you need access to accurate reports that are extracted from a high volume of data. Compiling data and manually creating reports is not only a tedious and time-consuming task, but it can also lead to errors. 

By implementing business process automation in your organization, you can automatically create accurate reports that can be updated in real-time whenever the data associated with them is changed. Getting rid of manual reporting means your team will have more time to focus on critical business tasks.

Following Necessary Compliances

Depending on the type of industry your business is a part of, you are required to comply with some or the other kind of regulations. These compliances can often put a strain on IT resources. Instead, you can streamline the processes involved in giving auditors information about your company through business process automation tools. 

For instance, if your company is required to comply with data security and protection regulations, then you can encrypt data at all levels of the company through automation. At the same time, business automation also creates transparency and stops the blame game within the company, as you can see precisely who approved what step of the process.

Waiting on Approvals

Depending on how the documents are shared and saved in your company, teams may have to wait for approval from the higher-ups before they can start the work, which can often lead to delays. In case someone is on leave or out of the office, it can disrupt everyone else's schedule.

How Non-Tech Professionals Can Launch Profitable AI Businesses Without Coding

We help professionals & business owners start & scale AI-driven businesses by leveraging existing AI tools and our proprietary AI operating system at ai-clients.com. You don't need to have a technical background, invest any significant capital up-front, or work what feels like another 9-5 job, because AI does a lot of the heavy lifting for you. 

Check out a free training to see how I used this exact system to go from a burned-out corporate director to making $500,000 per month in under 2 years. Feel free also to book an AI strategy call with one of our consultants to see how you could use your existing skills & experience to start a successful AI business.

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17 Challenges of Business Process Automation

People Working -  Challenges of Business Process Automation

1. Organizational Change Fatigue

The primary challenge that hinders companies in their digital transformation journey is the all-too-familiar weight of change fatigue. Change, a natural part of our human experience, often feels daunting, especially when past management shifts have left scars of uncertainty. What often frightens people the most is the uncertainty tied to transitional phases. 

A helpful approach to managing this anxiety is to communicate all forthcoming changes to employees. Everyone in the organization needs to understand the value these changes bring. When individuals are unclear about the “why” behind the shifts, their willingness to engage diminishes. How can leadership facilitate a smoother transition during this process? 

Change Management in Automation: Preparing Teams for a Smooth Transition

They should proactively introduce significant changes well in advance, engaging everyone impacted by the shift. By planning for upcoming changes, guiding individuals through each stage, soliciting their feedback, and ensuring a sense of mental safety, leaders can make the automation initiatives far more manageable. While these steps may seem basic, they play a crucial role in easing the transition.

2. Disjointed Business Processes

One significant barrier to practical automation efforts is the fragmentation of processes. When companies pilot or implement automation initiatives, different departments and units often operate as isolated entities. While this separation is understandable for department-specific changes, the absence of organization-wide process unification can complicate the entire automation endeavor, leading to chaos. Utilizing random tools and automating processes “here and there” may create even greater gaps in the system. 

To address this issue, companies should first examine how work is currently performed. Understanding your starting point makes it easier to determine the right direction. Once there is a clear overview of existing operations and the most pressing problems are identified, it becomes simpler to prioritize changes that will yield the highest impact.

3. Lack of Readiness for a New Work Reality

An apparent yet challenging factor is the lack of readiness for change. The new work environment, where humans collaborate with robots and AI, demands a different approach and mindset from both leadership and employees. Soon, every modern team or unit will consist of both traditional and digital workforces, working together on projects and enhancing each other’s capabilities. 

This shift means that employees will need to be adaptable and quick to learn, while hiring for automation projects may become slow and difficult. It is crucial to understand that robots do not replace humans, at least in the foreseeable future; rather, they serve to assist and support us. Machines and robots will primarily handle low-level transactional tasks that do not demand human intelligence. 

Upskilling for an AI-Driven Future: Preparing Employees for Creative and Cognitive Roles

As a result, individuals will have increased opportunities to engage in more creative and innovative work that is non-manual. This shift clearly demands a different skill set from employees, making upskilling essential to prepare them for significant workplace changes. 

Many software applications require specific qualifications and comprehensive training programs. Therefore, qualities such as open-mindedness, adaptability, and a high tolerance for ambiguity will be highly valued in employees.

4. Complexity of Existing Processes

One of the primary challenges in process automation is dealing with the complexity of existing business processes. Many organizations have accumulated a multitude of manual and semi-automated processes over the years, resulting in a tangled web of dependencies and inefficiencies. 

Automating these complex processes requires a deep understanding of the existing workflows, as well as the ability to identify opportunities for optimization and standardization. To overcome this challenge, businesses need a robust process automation platform that offers advanced modeling and visualization capabilities.

5. Integration with Legacy Systems

Another significant challenge in process automation is integrating automated workflows with legacy systems and heterogeneous IT environments. Many businesses rely on a diverse array of applications, databases, and technologies, making seamless integration a daunting task. 

Incompatibility issues, data silos, and disparate systems can hinder the smooth execution of automated processes, leading to inefficiencies and operational disruptions.

6. Scalability and Flexibility

As businesses grow and evolve, their process automation needs also change. Scalability and flexibility are crucial considerations when implementing process automation, as rigid, inflexible solutions can become barriers to growth and innovation. 

Businesses require process automation platforms that can adapt to evolving requirements, accommodate new process variants, and scale seamlessly to support increasing workloads and complexities.

7. Compliance and Security

In industries with stringent regulatory requirements, compliance and security concerns are paramount when implementing process automation. Ensuring that automated processes adhere to industry regulations, data privacy standards, and security best practices is crucial for: 

  • Maintaining trust
  • Mitigating risk
  • Avoiding legal repercussions

Businesses must prioritize compliance and security considerations throughout the automation lifecycle to safeguard sensitive data and maintain the integrity of their processes.

8. Automating for the Sake of Automating

A common challenge is that some businesses seek to automate business processes because they have been told to do so by a board/consultants, etc. I believe that organizations shouldn’t just automate for the sake of automating; they should automate for business outcomes. 

We all want outcomes, ROI, quick wins and success stories from automation, so my tip would be to set goals when automating any process, you can then measure the improvements within the performance reporting area of your DPA tool.

9.  Building a Business Case

I often speak with professionals eager to implement process automation, but many hesitate, understandably so. Building a compelling business case can be time-consuming, politically delicate, and risky for the person driving the initiative. But don’t let that stop you.

According to Gartner’s 2024 Global Software Buying Trends report, the software evaluation process typically takes around five months, with most decisions falling within the one to six-month range. Buyers usually shortlist four vendors, and the top priorities when selecting software are pricing and security.

Building a Strong Business Case for Process Automation

To give your proposal the best chance of success, follow these recommended steps, many of which software vendors can support you with:

  • Define the problem: Identify the team or department where automation will deliver the most value. Pinpoint repetitive, time-consuming, or error-prone tasks that hold up progress and impact productivity.
  • Quantify the cost of inaction: Estimate how much time is lost due to manual inefficiencies and translate that into a financial cost to the business, such as: 
    • Delays
    • Errors
    • Misplaced paperwork
  • Conduct thorough research: Explore automation solutions using a structured evaluation checklist to ensure you're comparing relevant tools and features.
  • Build a cost analysis: Outline the total cost of implementation, project the cost savings over time, and calculate your expected Return on Investment (ROI).
  • Map out your plan: Identify key stakeholders, establish roles and responsibilities, and develop a clear roadmap for implementation.
  • Present your case: Share your plan with decision-makers, focusing on how automation aligns with: 
    • Business goals
    • Reduces risk
    • Drives measurable impact

10. Finding the Ideal Business Process Automation Tool

Choosing the right Digital Process Automation (DPA) tool can be challenging; there are countless options available. For instance, Gartner Peer Insights lists 96 providers of process automation tools, while G2 features 116 process management tools and 92 listed under Digital Process Automation.

At FlowForma, we regularly support leaders in business improvement, transformation, and innovation. Based on this experience, we’ve identified key considerations to keep in mind when selecting a digitalisation tool for your processes.

Recommendations for Selecting a DPA Tool

  • Clarify your objectives and outcomes: Define what you want to achieve, whether it's: 
    • Reducing manual work
    • Improving compliance
    • Accelerating workflows
  • Use a structured checklist: This ensures you're consistently evaluating features and capabilities that align with your specific needs.
  • Trial your shortlist: Engage with a free trial or proof of concept to assess usability, integration, and impact before committing.
  • Leverage trusted review platforms: Use resources like G2 to gain insights from real user experiences and make informed comparisons.

11. Choosing the Right Business Processes to Automate

One of the most common challenges in process automation is deciding which processes to prioritise. Every organisation has its own structure, goals, and constraints, so there’s no one-size-fits-all approach. 

Typically, teams adopt one of the following strategies when introducing a new automation tool:

  • The big bang approach: Automating 50+ processes and launching them all at once.
  • The phased approach: Rolling out a few automated processes each month to maintain control and flexibility.
  • Focus on high-value processes: Targeting automation where it will drive the most measurable impact.
  • Tackling complexity first: Automating complex, multi-step processes that strain resources.
  • Quick wins: Starting with simple, repetitive tasks that are easy to automate and demonstrate value early.

Processes That Deliver Big Impact

There’s no right or wrong approach, but we recommend prioritising processes that free up your team to focus on strategic, high-impact work. 

Look for areas that:

  • Consume a high number of employee hours
  • Involve repetitive, manual tasks that are prone to error
  • Are essential for compliance or risk management
  • Cause delays or inefficiencies in cross-department workflows

The goal is to improve efficiency without disrupting business continuity. Start with challenges that, once solved, will: 

  • Unlock time
  • Reduce costs
  • Enhance customer experience

12. Choosing the Right Business Processes to Automate

One of the most common challenges in process automation is deciding which processes to prioritize. Every organization is unique, and so is its approach to automation. 

When adopting a new tool, teams typically follow one of several strategies:

  • The ‘big bang’ approach: Automating 50+ processes and launching them all at once.
  • The gradual approach: Introducing a small number of processes each month for greater control and scalability.
  • Focusing on high-value processes: Prioritizing workflows that directly affect the bottom line or customer experience.
  • Targeting complexity: Choosing complex, resource-intensive processes where automation can relieve pressure.
  • Quick wins: Starting with simple, repetitive tasks that are easy to automate and roll out rapidly.

Prioritizing for Impact

There’s no one ‘correct’ strategy, but we recommend starting with processes that will release valuable time and resources. 

Focus on areas that:

  • Require significant manual effort from large teams.
  • Are prone to human error or inefficiency.
  • Are essential for regulatory compliance.
  • Cause operational delays or customer dissatisfaction.

The goal is to improve efficiency while creating space for more strategic, high-impact work. The possibilities are extensive, so consider which problems, once solved, would deliver the greatest value first.

13. Vendor Dependence

A challenge that can be faced with process automation is an over-dependence on a vendor or partner. I have heard of companies who use process automation tools that have very high complexity and are not intuitive enough for business people to digitalize with, which means that they need to outsource a lot of their digitalization projects to the vendor or a partner, this can be a challenge regarding additional costs incurred and delays in waiting for the projects to be completed as they are relying on external resources. Another challenge with dependence on vendors or partners is the lack of agility.

14. Inability to Scale Automation

So far, most businesses are automating simple, repetitive tasks within a single process. Basic automation tools like Robotic Process Automation (RPA) can be highly effective at undertaking these specific tasks, increasing efficiency and cutting costs at a local or departmental level. 

Tasks commonly completed by RPA include: 

  • Logging into applications 
  • Extracting data 
  • Filling in forms 
  • Matching POs to invoices 
  • Compiling routine reports

Why Scaling RPA Requires Intelligent Automation

But this type of automation is designed to scale across multiple processes, business functions, or markets, because RPA bots are limited to their specific tasks and cannot adapt to system changes. To scale automation, bots need an additional layer of intelligence to tell them what to do, how to do it, and when to do it. 

AI-powered intelligence, from technologies such as process mining, can provide a level of situational awareness that enables automation to be applied more widely and effectively across your business. By taking data, processing it, and determining what needs to be done, intelligent automation can drive real business value at scale.

15. Lack of Transparency in Automation

One of the biggest mistakes businesses make when automating processes is setting up automations and leaving them to run without sufficient testing, transparency, or traceability. 

To avoid this situation, there are three steps you should take when automating processes:

  • Automation testing: thorough testing of any automation will help you ensure you are achieving the results you expect, and not unintentionally automating sub-optimal processes or inefficiencies. 
  • Automation auditing: Continually auditing automated processes in real time is essential to make sure automations continue to run as intended. Automation discovery and impact analysis will allow you to debug processes and handle any errors. 
  • Automation tracking: By tracking the impact of your automation efforts, you can understand the value they are generating. You should be able to instantly pull results to share with anyone who needs to see them.

16. Costs and Budget Constraints

The initial investment required for acquiring process automation tools, software development, infrastructure upgrades, and employee training can drain organizational budgets. 

The challenge extends beyond the initial costs, encompassing ongoing expenses for: 

  • System maintenance
  • Updates
  • Potential scalability needs

Budget constraints may force organizations to prioritize specific processes over others, potentially overlooking opportunities for comprehensive automation. To mitigate this challenge, strategic financial planning, deep cost analysis, and a clear understanding of the transformative impact that well-implemented process automation can have on overall organizational performance are necessary.

17. Customization Complexity

The complexity associated with tailoring automation systems according to your business requirements can be a complex challenge to solve. Organizations need to accommodate diverse processes, each with its own set of rules, exceptions, and variations. 

It takes time, skills, and advanced capabilities to achieve this level of customization without compromising cost, integrity, and coherence. That is why when you look to adopt a new technology, you should make sure that it gives you the flexibility and customization needed before investing time and money into it.

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Overcoming Process Automation Challenges

Man Thinking -  Challenges of Business Process Automation

Communication and Collaboration: The Backbone of Automation Success

Effective communication and collaboration are critical to the success of automation projects. Businesses should engage with key stakeholders and employees to build consensus and reduce resistance to change. Cross-functional teams should be formed to ensure collaboration and alignment across departments. 

Proper Planning and Execution: Setting the Stage for Automation Success

Proper planning and execution are critical for the success of automation projects. Businesses should develop a clear roadmap and timeline, identifying potential risks and challenges. They should prioritize automation initiatives based on their potential impact and ROI. Process intelligence software can help you identify process automation opportunities and track progress throughout your initiatives. 

Embrace Change Management: The Key to Overcoming Process Automation Fatigue

A third crucial aspect to overcome process automation fatigue is a persistent effort in change management. Many people may feel threatened or frustrated by automation taking away work tasks. It’s essential to communicate the benefits of process automation, as well as educate and inform employees of the ways automation can free up time and resources for more meaningful work. 

Change is Inevitable, But Resilience and Agility Are a Must

Regardless of the industry or location, any company with employees engaged in knowledge work will need to embrace business process automation in the coming years. It’s no longer just a nice-to-have; it’s a powerful tool that can enhance job efficiency and boost competitiveness when implemented correctly. 

Automation is much more than just robots assisting people; it is a whole new way of working that ensures better systems and automated workflows. 

Driving Purposeful Automation in a Fast-Moving Landscape

The key factor here is speed. It’s vital to have a strategic plan and a clear vision of the desired outcomes, ensuring that the company pursues automation with a purpose rather than following the crowd. 

Given the rapid pace of change and uncertainty, speed is essential not only to stay ahead of competitors but also to maintain sustainable growth.  

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Business process automation has been around for a while now. But with the recent emergence of AI tools, the way we automate processes is drastically changing. Today’s automation solutions come equipped with artificial intelligence that not only streamlines repetitive tasks but also learns as it goes, improving accuracy and efficiency over time. 

This is what makes starting and scaling an AI-driven business so appealing. You can leverage existing tools to automate your operations, cut costs, and deliver the best results to your clients. At AI Acquisition, we show you how to do it.

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Check out a free training to see how I used this exact system to go from a burned-out corporate director to making $500,000 per month in under 2 years. Feel free also to book an AI strategy call with one of our consultants to see how you could use your existing skills and experience to start a successful AI business.

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