Humanoid Robots in Factories: Hype vs. Reality

Daily Technology

22/01/2026

The vision of humanoid robots seamlessly integrating into factory floors is encountering significant real-world obstacles. Despite considerable investment and high-profile demonstrations from companies like Tesla and Figure AI, the widespread adoption of these advanced machines in manufacturing and supply chains may be considerably further off than anticipated.

Key Takeaways

Fewer than 20 companies globally are expected to deploy humanoid robots at scale in manufacturing and supply chains by 2028.
Current humanoid robot technology faces limitations in battery life, dexterity, and cost-effectiveness.
"Polyfunctional" robots, often on wheels, are emerging as a more pragmatic solution for many industrial tasks.
A significant skills gap among the workforce poses a challenge to the effective implementation of advanced automation.
Safety concerns and high costs remain major hurdles for widespread humanoid robot adoption.

The "Pilot Purgatory" of Humanoid Robots

Supply chain leaders have been exploring robotics as a solution to labor shortages and rising wages. However, Gartner forecasts that by 2028, fewer than 100 companies will move their humanoid robot projects beyond the testing phase. The core issue lies in the disconnect between the demands of factory environments and the current capabilities of the technology. Analysts caution that the excitement surrounding humanoid robots is outpacing their practical applicability for demanding logistical work.

Physical and Dexterity Challenges

The hurdles are not solely software-based but deeply rooted in physical limitations. Research indicates that most humanoid robots can operate for only 90 minutes to two hours on a single charge, falling far short of the extended shifts required in factories. Furthermore, achieving human-level dexterity, particularly in robotic hands, is prohibitively expensive. Even with high costs, these hands often struggle to handle complex objects reliably.

The Rise of Polyfunctional Robots

In contrast to the hype surrounding humanoid forms, pragmatic manufacturers are increasingly turning to "polyfunctional" robots. These machines often prioritize efficiency and stability, utilizing wheels for mobility and incorporating sensors strategically. Gartner analysts suggest these non-humanoid robots are better suited for many industrial jobs, offering a superior return on investment for companies focused on maximizing throughput.

Workforce Readiness and Skills Gap

Another significant barrier to advanced robot integration is the readiness of the human workforce. Successful automation requires skilled personnel to maintain and operate complex machinery. Gartner predicts that a lack of investment in learning and development will cause 60% of supply chain digital adoption efforts to fail to deliver promised value by 2028. Without adequate training, even advanced robots may not achieve their full potential.

Safety and Cost Concerns

For many businesses, the cost of humanoid robots remains a significant deterrent. While some manufacturers aim for lower price points, entry-level models often lack the durability for factory settings, and more advanced versions are considerably more expensive than specialized industrial machines. Safety is also a paramount concern. Unlike traditional caged industrial robots, humanoid robots are designed to operate near people, but their active stability systems and mass create unique fall and collision risks, necessitating entirely new safety frameworks. Experts also note that these robots often lack the "common sense" required for unpredictable real-world environments.

The Path Forward: Pilot Programs and Specialization

While most experts agree that humanoid robots will eventually play a role, their immediate application is likely to be in controlled environments rather than dynamic warehouses. Gartner advises supply chain leaders to conduct thorough pilot programs to assess the suitability of humanoid robots for their specific needs, cautioning against immediate expectations of staff reductions. The recommendation is to focus on automation that addresses specific problems with the most effective robot type for each task, while the broader industry continues to invest in specialized, polyfunctional automation for reliable, immediate returns.

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