What is Robotic Process Automation (RPA) & how does it work?

American manufacturers and logistics operators lose thousands of hours annually to repetitive digital tasks; hours that could drive innovation, growth, and competitive advantage. Robotic process automation reclaims that time.

This guide explains how RPA works, where it delivers the biggest operational wins for American producers, and when deployment makes strategic sense.

What is RPA?

Robotic process automation (RPA) is software that mimics human actions on a computer to automate repetitive, rule-based tasks. It uses bots (software programs) that click, type, read screens, and move files faster and without errors or fatigue.

RPA bots execute the same sequence of actions repeatedly with zero deviation. A mid-sized aerospace parts supplier reduced order processing from 4 hours to 12 minutes. This frees up operators to focus on quality control and customer relationships. Invoice processing that requires manual checks runs continuously without oversight.

How RPA has evolved with AI and agentic automation

Traditional RPA follows rigid rules without learning. It executes the same steps repeatedly, which works perfectly for straightforward tasks, but it fails when inputs vary.

A blurred invoice or an ambiguous customer’s email stops execution. Traditional RPA bots cannot handle variations without reprogramming.

Modern RPA solves this by integrating AI capabilities, a fundamental shift in how American operations compete:

• OCR reads documents that stop basic RPA systems.
• Natural language models interpret ambiguous inputs and extract necessary data.
• Classification models sort inconsistent data into proper categories.

Agentic automation represents the next evolution: shifting control from scripted steps to goal-based execution.

Instead of scripting every single click and keystroke, operators define an objective goal. For example, “Process this customer return completely.”

A capable agentic system:

• Breaks down the goal into smaller, manageable tasks like “Find the original order,” “Check current inventory levels,” and “Issue the credit to the customer's account.”
• Identifies necessary tools, which might include existing RPA bots, API connections to another system, or direct database lookups.
• Executes steps dynamically, determining the optimal path as work progresses.
• Handles obstacles intelligently. If an inventory system goes down, the system attempts an alternative approach or alerts operators with proposed solutions instead of simply failing.

How does RPA work?

RPA converts manual processes into automated workflows that execute continuously with sub-second response times and repeatability rates exceeding 99.9%.

The system has three main components:

1. Bot software: Your digital operator that runs on a desktop, virtual machine, or server. It clicks buttons, types text, reads information from screens, and moves files—executing tasks with zero deviation.
2. Workflow script: Mission parameters defined with engineer-level precision, specifying exactly what steps to follow. For example, Open email → download attachment → extract invoice total → update ERP system.
3. Executor: Central command that schedules bots, assigns tasks, manages login credentials, and monitors performance across your entire operation.

Types of RPA bots

RPA bots operate differently depending on how they interact with humans and handle tasks.

1. Attended bots run on operator workstations and work alongside human workers. They handle tasks needing human input. An attended bot might pull up customer information while an operator is on a call.
2. Unattended bots run in the background without human intervention. Perfect for fully automated work running on schedules, they process invoices overnight or generate daily reports.
3. Hybrid bots switch between attended and unattended modes. They manage mostly automated workflows that occasionally need human judgment.

RPA implementation process

Deploying RPA requires careful planning and execution. Here's the proven approach forward-thinking manufacturers use:

• Identify tasks: Start with repetitive, rule-based work where the steps rarely change. Invoice processing, data entry, and customer onboarding work well. Simpler tasks make better first automation projects.
• Pick your platform: Look for tools with intuitive interfaces and no-code functionality. Platforms with templates and pre-built bots significantly reduce implementation time.
• Map workflows: Document exactly what the bots will do, step by step. Specify where data comes from, what transformations occur, and how exceptions are handled. Every detail matters at this stage.
• Develop and test: Build your bots and test them thoroughly in controlled environments. Catch issues before they affect production systems or real customer data.
• Deploy and monitor: Release bots into live environments, then track performance closely. Regular monitoring ensures bots deliver expected value and catches issues early.

Key considerations when implementing RPA

RPA delivers measurable productivity gains across American manufacturing operations, but requires careful evaluation before deployment:

• Is the ROI justified? Calculate the time bots save, labor cost reductions, and workflow improvements.
• Are your processes stable? If workflows change frequently, bots require constant updates and may break regularly. Well-defined processes make the best candidates.
• How will your team respond? The prospect of automation can create anxiety about job security. RPA doesn't replace your team; it elevates them. Operators shift from repetitive data entry to process optimization, quality oversight, and customer problem-solving. This is workforce multiplication, not workforce reduction. Communicate clearly how RPA improves work quality and allows team members to focus on higher-value activities.
• Is your vendor reliable? Choose vendors with strong customer support, regular platform updates, training resources, and active user communities.

Benefits of RPA

The compelling benefits of RPA include speed, accuracy, cost savings, and compliance. 

• Speed: Bots work continuously without breaks. They complete tasks in a fraction of the time it takes humans.
• Accuracy: Bots eliminate human error from repetitive tasks. No typos, no skipped steps, no forgotten details.
• Cost savings: Processing capacity scales linearly without proportional cost increases. Automating high-volume tasks significantly reduces labor costs. 
• Compliance: Bots consistently follow your compliance rules, including data-handling requirements, approval workflows, and documentation standards. Many RPA platforms also automatically create detailed audit trails.

Challenges and limitations of RPA

Now that we’ve looked at the benefits, here are the limitations you should be aware of:

• Scaling challenges: RPA excels at repetitive jobs with clear rules. Processes with too many variables or frequent exceptions are harder to automate.
• Implementation complexity: Mapping workflows, configuring bots, and integrating with existing systems takes time and expertise. Bots also require ongoing maintenance and updates as systems change.
• Decision-making limitations: When faced with ambiguous data or situations requiring judgment, bots can't adapt. Tasks requiring intuition, creativity, or contextual understanding still need human involvement.
• System dependency: If an application's UI gets an update, bots may break.

Common applications of RPA

RPA delivers value across American manufacturing, logistics, and operations:

• Data entry: Bots transfer data between systems significantly faster than manual entry. They handle large datasets while automatically cleaning up inconsistencies.
• Invoice processing: RPA reads invoices using OCR, populates the correct fields in accounting systems, and cross-checks for errors or mismatches against purchase orders.
• Customer service: Bots handle frequently asked questions, send account updates, and route complex cases to human agents. They provide consistent service 24/7 without variation in quality.
• HR tasks: RPA simplifies onboarding by automating background checks, payroll setup, and welcome communications. It also keeps employee records current by updating information across multiple systems.
• Finance operations: Bots reconcile transactions, flag discrepancies, and ensure financial accuracy.

Popular RPA tools

American operations teams deploy several core RPA platforms:

• UiPath offers its accessible interface and extensive capabilities. Studio gives control without requiring deep programming knowledge, and the activity library covers most day-to-day business workflows. It handles both attended and unattended bots, as well as agentic automation.

• Automation Anywhere provides a cloud-first setup. It’s great for unattended workloads and gaining visibility into bot performance.
• Blue Prism works best for large enterprises that need strict oversight. It offers strong governance, auditing, and control, which makes it common in regulated industries. The trade-off is a steeper learning curve.
• Microsoft Power Automate fits naturally into organizations already using Microsoft. Desktop flows cover RPA tasks, while cloud flows handle API-based workflows.

Industries where RPA is thriving

RPA delivers value wherever teams handle repetitive work, legacy systems, or rules-driven processes. These industries include:

• Banking: Bots manage account maintenance, KYC (Know Your Customer) verification, loan processing workflows, and back-office reporting.
• Healthcare: RPA processes insurance claims, retrieves patient records, and schedules follow-up appointments.
• Telecom: Bots handle billing operations and customer data updates for accurate invoicing and current records.
• Retail: RPA assists with price updates, inventory synchronization, returns processing, invoice matching, and order fulfillment.
• Insurance: Insurers deploy RPA across underwriting, claims intake, policy updates, and document processing workflows.

Summing up

RPA reclaims thousands of hours that American operations teams spend on repetitive digital tasks. It updates legacy systems without rebuilding them, a practical path forward for manufacturers working with established infrastructure. Modern AI and agentic tools interpret exceptions, read unstructured inputs, and make decisions that traditional rule-based bots cannot.

RPA handles the digital side. Physical automation handles the shop floor. Together, they form the foundation of modern American manufacturing, where human expertise drives strategy, and automation handles execution. This is how American facilities maintain a competitive advantage.

RPA manages software processes. Standard Bots robots automate the shop floor. Together, they cover both digital and physical operations.

Next steps with Standard Bots’ robotic solutions

Looking to upgrade your automation game? Standard Bots Thor is built for big jobs, while Core is the perfect six-axis cobot addition to any automated operation, delivering unbeatable throughput and flexibility.

• Affordable and adaptable: Core costs $37k. Thor lists at $49.5k. Get high-precision automation at half the cost of comparable robots.
• Perfected precision: With a repeatability of ±0.025 mm, both Core and Thor handle even the most delicate tasks.
• Real collaborative power: Core’s 18 kg payload conquers demanding palletizing jobs, and Thor's 30 kg payload crushes heavy-duty operations.
• No-code simplicity: Our intuitive, no-code app makes it easy to teach Standard Bots robots to do everyday tasks. So, Core and Thor integrate smoothly with your operations for advanced automation.
• AI-driven models: For complex, high-variance, and unpredictable tasks that are otherwise impossible to automate today, Standard Bots robots learn through our AI-driven vision-to-action models, similar to how full self-driving works.
• Safety-first design: Machine vision and collision detection mean Core and Thor work safely alongside human operators.

Schedule your on-site demo with our engineers today and see how Standard Bots Core and Thor can bring AI-powered greatness to your shop floor.

‍FAQs

1. Is RPA a form of AI?

RPA is not a form of AI. Traditional RPA follows fixed rules and does not learn or adapt on its own. AI becomes part of the workflow only when you combine RPA with tools like OCR, machine learning models, or agentic systems that can interpret data, classify inputs, or make decisions based on context.

2. Is RPA easy to learn?

Yes, RPA is easy to learn because it focuses on logic and workflow steps rather than programming. Platforms such as UiPath Studio and Power Automate use visual, drag-and-drop builders that let beginners create simple automations quickly. 

3. What are examples of robotic process automation?

Examples of robotic process automation include invoice processing, data entry, insurance claims intake, employee onboarding, order routing, and report generation. These tasks follow predictable rules and involve structured digital data, which makes them strong candidates for RPA bots.

4. How does RPA differ from BPM (Business Process Management)?

RPA automates individual tasks, while BPM defines and manages the full process from start to finish. You can think of BPM as the blueprint that defines how a process should work, and RPA as the automation that handles specific repetitive steps within that process.