How does your cap/closure influence the automation process?

Downstream automation is an important component of a successful manufacturing process.  There are real quantifiable improvements for closure manufacturers through projects that involve automation engineers because there is a "process design" that they are aware of that can influence the successful and efficient start-up of the automation equipment.

So how does your closure influence the automation process?  Here are just a few factors that can have an impact:

1. Mold design: 2 molds designed and built to produce the same part will most certainly not offer exactly the same parts, dimensionally speaking and from tolerance standpoint.  There have been cases where parts coming off one mold may work flawlessly in the downstream automation whereas parts of the second will not offer the same level of performance.
2. Single cavity mold vs production tool: prototype parts (of a single cavity tool) utilized to design, built and factory test automation will certainly differ from the production tool.  It is preferable to use final parts to minimize surprises during start-up.
3. Closures from multiple molds and presses: same issues again
4. Cycle time: this will most certainly have an impact on the closure's physical properties.
5. Part aging: caps and closures warm off the press will not react the same as the ones that have been stored in inventory. 
6. Closure color: colorants and additives can influence the physical properties of a closure and therefore not all colors will be processed exactly the same through the automation equipment.

As my boss says: "One of the most basic requirements for a successful automation is consistent incoming materials and components.  Automation equipment cannot correct the variability of the inputs; if anything, the variability is likely to increase as you try to marry 2, 3 or 4 components together, all with their own degrees of consistency."

What other factors can impact the automation process? I would love to read your point of view.