Evaluating Industrial Robots as A Strategy for Manufacturing Cost Optimization in Lafarge Cement Company, Calabar

The study evaluated the use of industrial robots as a strategy for manufacturing cost optimization at Lafarge Cement, Calabar, driven by the growing global demand for efficient, cost-effective, and technologically advanced manufacturing systems. The research focused on robotic adoption, its impact on production efficiency and product quality, cost reduction, and implementation challenges. Using a descriptive survey design, data were collected from a population of 1,124 technical and operations personnel, with a sample size of 287 determined via Taro Yamane’s formula and selected through proportionate stratified and purposive sampling across four departments. Primary data were gathered through structured questionnaires and semi-structured interviews, while secondary data were obtained from maintenance and production records spanning 2021–2025, sourced from maintenance logs and financial reports tracking key performance indicators such as equipment availability, mean time between failures, production efficiency, energy consumption, and product quality. Descriptive statistics (mean and standard deviation) and one-sample t-tests at a 0.05 significance level were used to analyze survey data, while secondary data were analyzed through trend analysis and comparative evaluation to assess pre- and post-robotics performance. These combined methods enabled a comprehensive evaluation of both survey responses and operational data. Findings indicated moderate robotic adoption (mean = 3.23), significant improvements in production efficiency and product quality (mean = 3.98), and meaningful cost reduction (mean = 3.90), with notable implementation challenges (mean = 3.90). Three of four null hypotheses were rejected, confirming robotics’ significant influence on efficiency, quality, and cost, while the hypothesis on adoption level was not rejected. The study concludes that industrial robotics have strong potential to optimize cement manufacturing operations but require overcoming structural and technical barriers, offering valuable insights for practitioners, policymakers, and researchers aiming to modernize manufacturing in emerging economies.