After comparing the outlines, I found that the proposed approach overlaps the door handle even though the workpiece itself clears. That explains the misleadingly comfortable result in my initial sketch.

Start from those measurements and review approach and withdrawal offline with the full tool, cables and maintenance access included. A revised mount then needs the integrator's assessment.

Our buyer says go bigger. Does that help, or just buy the same problem in a larger arm?

Going larger should open up mounting options. It might be the most straightforward option to explore.

Bigger could bring another obstruction. Extra reach won't shrink the gripper past that handle.

You're right; more mounting freedom isn't guaranteed. Check each candidate in the measured layout and only favour a larger arm if its full approach works better.

@PriyaAllen0307 On our separate machine job, the first pedestal position blocked a maintenance panel. The transfer looked excellent until the maintenance person asked how they'd open it.

@ThomasBaker0451 Your example prompted me to compare our proposed pedestal with the service panel opening. That revealed another overlap to correct in the layout.