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1、A global view of todays challenges and tomorrows opportunities to harness technology for greater resiliency,agility,and sustainabilityState of Smart Manufacturing Report EIGHTH ANNUALThis quote from our CEO,Blake Moret,resonates throughout the findings of our 2023 State of Smart Manufacturing Report

2、,which surveyed 1353 global manufacturers.The world has changed,and manufacturing has changed with it,but there is more to do.Skilled labor and labor of any kind continues to be elusive across the globe.As manufacturers continue to seek opportunities for profitable growth,theyre finding that uncerta

3、inty in workforce availability is impacting quality,along with their ability to meet their customers needs and transform at pace.They are addressing this impact by using technology to extract data from their operations and assemble actionable insights.We are also seeing how technology is helping the

4、 industry accelerate their agility and competitive differentiation.The clear message coming from this report is that manufacturers view technology as an advantage for improving quality,agility,innovation,and to attract the next generation of talent.Manufacturers expect to mitigate risk through techn

5、ology tied to processes and people to build resiliency and drive future success.I hope you find the report useful in benchmarking your organization against peers and as a catalyst for taking action to drive transformation that will deliver differentiated business outcomes in your industry.Before you

6、 dive into the results,here are some of my observations on the findings.2x as many respondents say they lack the technology to outpace the competition,compared to last years surveyRecent years have made a compelling business case for many newer technologies as disruption has demanded accelerated ado

7、ption.This unprecedented pace of change is creating competitive pressure across the industry.Sustainability and ESG are integral to ManufacturingOver 95%of respondents noted some level of sustainability and/or ESG policy over the last two years,whether formal or informal.Regulations are now applying

8、 pressure across the value chain for all companies to address sustainability and ESG in their operations.Smart manufacturing technology solutions can help.Over 50%more manufacturers are using Machine Learning/Artificial Intelligence compared to last yearThis number will continue to rise as manufactu

9、rers see the impact that accessible machine learning/artificial intelligence can have on their business.Improved quality,productivity,and engaging talent to use data driven insights for decision making are some of the benefits.A third of manufacturers are hampered by technology paralysis an inabilit

10、y to decide between solutionsTechnology is demonstrated throughout the report as being crucial to mitigating risk and delivering growth,so manufacturers must overcome indecision by choosing a partner with relevant expertise and experience who can advise and guide them in implementing a fit-for-purpo

11、se solution.97%of participants reported plans to use smart manufacturing technologySmart manufacturing solutions enable and optimize more agile,resilient production processes,empower the workforce,manage risk,drive sustainability,and accelerate transformation.While the landscape is not predictable,h

12、istory is clear in showing that adversity ignites innovation and creates opportunity.Manufacturers with the right vision,strategy,bias for action,and partners will seize this moment to outpace their competitors and forge a bright future.“Weve experienced 20 years of evolution in 2 years.”SEIZE OPPOR

13、TUNITIES FOR GROWTHVeena LakkundiSenior Vice President,Strategy and Corporate Development,Rockwell AutomationWith best wishes for a productive and successful 2023,INTRODUCTION 028th Annual State of Smart Manufacturing Report Introduction letter 02 Executive summary 04 A global survey 05 SECTION 1:Th

14、e current state of smart manufacturing 06 Industry obstacles and outlook 07 Technology is top response for risk mitigation 08 Complete supply chain solutions are lacking 09 Addressing workforce 10 Sustainability moves into the mainstream 11 Smart manufacturing adopted globally 12 Smart manufacturing

15、 solutions 13 SECTION 2:Manufacturers biggest challenges 14 Competitive differentiators for manufacturers in 2023 15 Leadership and the modern workforce 16 Increasing quality and profitable growth 17 A switch in sustainability focus 18 Cybersecurity awareness and preparedness 19 Investing in the rig

16、ht tools and technology 20 Overcoming technology paralysis 21SECTION 3:The future of smart manufacturing 22 Smart manufacturing holds the key to future success 23 Top investments:Cloud/SaaS and process automation 24 Workforce of the future 25 Cloud continues to soar 26 Quality is driving digital tra

17、nsformation 27 Quality matters most in sustainability 28 Data:Unlocking a competitive opportunity 29 The future of manufacturing technology 30SECTION 4:Taking action 31 Getting started guide steps 32 Ten steps to technology adoption(checklist)33 SECTION 5:Demographics and firmographics 34 Industry/A

18、nnual revenue 35 Seniority/Department 36 Worldwide locations we serve 37TABLE OF CONTENTS INTRODUCTION 038th Annual State of Smart Manufacturing Report EXECUTIVE SUMMARY Manufacturers Embrace Technology As manufacturers embrace smart manufacturing,they are collecting more and more potentially valuab

19、le data.However,if data is siloed in separate systems,or the requisite skills for analyzing insights are lacking,manufacturers cant fully capitalize on the data they hold.The#1 way manufacturers plan to drive positive business outcomes over the next five years is through better use of data analytics

20、 40%-the year-over-year increase in manufacturers who believe they lack the ability to use data to make decisions to outpace the competition 97%of participants reported plans to use smart manufacturing technologyProfitable growth without sacrificing quality As we emerge from the pandemic,the renewed

21、 drive for growth and expansion is rising higher up the agenda.What comes through loud and clear from manufacturers,however,is that they are determined not to sacrifice quality in the pursuit of maximizing revenue and profit.According to respondents,the#1 internal obstacle they face in 2023 is balan

22、cing profitable growth and quality 45%of respondents believe a push for higher quality is creating the need to accelerate digital transformation in their organizations When asked where artificial intelligence will have the most impact on manufacturing,quality(closed-loop control,in-line quality)topp

23、ed the list ahead of automation,forecasting,and tracking&complianceOutpacing the Competition There is a growing sense that manufacturers who can attract,retain,and upskill the right team will outperform competitors.Alongside workforce concerns,implementing the right processes and technology are reco

24、gnized as competitive differentiators within the manufacturing industry.Skilled workforce remains a top concern and is the#1 reason why manufacturers believe they cant outpace the competition in 2023 Almost 2x as many respondents say they lack the technology to outpace the competition,compared to la

25、st years survey 79%of manufacturers lack a complete supply chain planning solutionINTRODUCTION 048th Annual State of Smart Manufacturing Report The 8th annual edition of the State of Smart Manufacturing report surveys the broadest audience yet,probing deeply into global manufacturing.This report has

26、 expanded in scope from previous years,with quadruple the number of respondents,across 13 of the top manufacturing countries;25%of whom work for firms with over$1B in revenue.Participants,who hold positions from management up to the C-suite,responded to questions that reveal the current state of tec

27、hnology in manufacturing,the biggest challenges,and the future of the industry.This report from Rockwell Automation,in association with Sapio Research,includes a technology adoption plan alongside the research findings to help you turn insights into action.WHAT IS SMART MANUFACTURING?Smart Manufactu

28、ring is the intelligent,real-time orchestration and optimization of business,physical,and digital processes within factories and across the entire value chain.Resources and processes are automated,integrated,monitored,and continuously evaluated based on all available information as close to real tim

29、e as possible.A global survey of over 1,350 manufacturers reveals a focus on delivering profitable growth without sacrificing quality,an emphasis on accessing datas true potential,and increasing adoption of technology to build resilience,enable agility,and increase sustainability.MESA International

30、INTRODUCTION 058th Annual State of Smart Manufacturing Report THE CURRENT STATE OF SMART MANUFACTURINGManufacturers are navigating a complex landscape:Aiming for profitable growth without sacrificing quality;building greater resiliency,agility,and sustainability both inside the organization and beyo

31、nd;and tackling workforce and supply chain issues simultaneously.One thread runs through it all:the need for technology to mitigate risks,open up new opportunities,and remain competitive.SECTION 1:068th Annual State of Smart Manufacturing Report Inflation,the pandemic,and supply chain disruption wer

32、e named as the top three external forces to have dampened growth during 2022.Looking ahead to 2023,participants expect the impact of the pandemic to wane,while inflationary pressures are set to rise.This surveys findings point to the necessity of making strategic investments in technology to counter

33、 the economic squeeze.Q.What do you see as the biggest external obstacle(s)to your organizations growth for calendar year 2023?Select top 5Q.What do you see as the biggest internal obstacle(s)to your organizations growth for calendar year 2023?Select top 5INDUSTRY OBSTACLES AND OUTLOOK SECTION 1:THE

34、 CURRENT STATE OF SMART MANUFACTURING“The manufacturing industry has maintained its rapid pace of change and disruption,making the ability to adapt a premium.Manufacturers have encountered many challenges in their efforts to become more resilient while maintaining efficiency,but one of the most cite

35、d issues are outdated/legacy systems.While the predictions highlighted touch upon many areas of the business,the main theme that can be tied back to is having the proper digital infrastructure in place to serve as the foundation for transformation.”Reid Paquin Research Director,IDC Manufacturing Ins

36、ights IDC FutureScape:Worldwide Manufacturing 2023 Predictions Technology Industry Obstacles and OutlookEXTERNALInflationShortage of skilled workersCybersecurity risks(e.g.,ransomware,phishing)Raw materials/microchip shortage/pricesSupply chain distributionImpact of COVID-19 pandemicINTERNALBalancin

37、g quality and growthUsing and understanding data to improve the businessOnboarding new employeesWorker retention/knowledge retentionDeploying and integrating new technologyProduct qualityBase:1353078th Annual State of Smart Manufacturing Report Manufacturers are turning to technology to tackle the r

38、isks that exist both inside and outside the organization.The top two ways respondents are addressing internal risk are to adopt new technology aimed at minimizing disruption from workforce or supply issues(53%)and to shift their operations to the cloud for purposes including increased cybersecurity

39、protection and business continuity(50%).When it comes to external risks like inflation,supply chain,and workforce shortages,the top-ranking mitigation tactic is adopting new technology(44%).09TECHNOLOGY IS TOP RESPONSE FOR RISK MITIGATIONQ.How is your organization currently mitigating the internal r

40、isk mentioned in the previous questions?Select top 5Q.How is your organization currently mitigating the external risk mentioned in the previous questions?Select top 5Base:1353SECTION 1:THE CURRENT STATE OF SMART MANUFACTURINGAdopting new technology Digitizing business through software adoption and a

41、utomationFinding alternate materials or suppliers to meet demand Adopting software for automating processes and tracking/quantifying sustainable practicesEnsuring data accuracy for reporting and informed decision-making Managing cybersecurity risks(e.g.,ransomware,phishing)Shift to cloud operations

42、for data backup,business continuity,eliminate data/communication silos,added cybersecurity protection,etc.Mitigate external risksMitigate internal risks088th Annual State of Smart Manufacturing Report Despite being impacted by supply chain disruption in recent years,4 out of 5 manufacturers lack end

43、-to-end supply chain planning.End-to-end software solutions are designed to address problems faced by manufacturers,such as keeping costs down while managing redundancy and resiliency in the supply chain which they do by incorporating sales and operations planning,while also increasing visibility an

44、d control.Piecemeal solutions often dont contain enough inputs to accurately plan and forecast.50%of participants are either not using a supply chain planning process or are using manual tools(i.e.spreadsheets)or homegrown solutions,placing a large IT burden on the company and introducing a risk of

45、obsolescence.The lack of visibility faced by those without end-to-end digital supply chain solutions will prove problematic,especially in the face of growing pressure from regulatory bodies,along with audit demands from large customers that now require tracking and traceability transparency.COMPLETE

46、 SUPPLY CHAIN SOLUTIONS ARE LACKINGSECTION 1:THE CURRENT STATE OF SMART MANUFACTURINGQ.To what extent does your organization currently perform supply chain planning?Select oneBase:1353Gartner Ebook,Elevate and Expand Your Smart Manufacturing Strategy,2022.“As automation of data and information flows

47、 expands beyond the factory,the need to manage supply chain convergence grows.Gartner defines supply chain convergence as the synchronization of processes,subprocesses and activities across the supply chain.It requires breaking down the departmental or functional barriers that exist between organiza

48、tions.For smart manufacturing,this means evaluating the processes used in logistics,planning and sourcing,and customer service against those used in manufacturing operations,and designing cross-functional performance metrics to assess total value generated for the customer.”79%of manufacturers lack

49、end-to-end supply chain planning softwareGARTNER is a registered trademark and service mark of Gartner,Inc.and/or its affiliates in the U.S.and internationally and is used herein with permission.All rights reserved.098th Annual State of Smart Manufacturing Report Complex issues such as dealing with

50、a shortage of skilled workers and the need to train employees on new processes at speed require modern approaches.More than two-thirds of manufacturers believe that technology can be very helpful,or extremely helpful,in addressing these types of workforce challenges.ADDRESSING WORKFORCE But technolo

51、gy cannot drive success without people and vice versa.SECTION 1:THE CURRENT STATE OF SMART MANUFACTURINGQ.By increasing our use of technology in the next 12 months,my organization will:Select one Base:1353Technologys Impact on the WorkforceNeed to hire more workers31%36%Repurpose existing workers to

52、 new or different roles11%Need to hire fewer workersHire new workers for different roles17%4%Make no change to staffing89%of manufacturers expect to maintain or grow employment as a result of technology adoption108th Annual State of Smart Manufacturing Report Sustainability and environmental,social,

53、and governance practices(ESG)have moved into the spotlight in recent years.The proliferation of new or strengthened regulatory frameworks,such as the International Sustainability Standards Board(ISSB),the EUs Sustainable Finance Disclosure Regulation(SFDR),and Taxonomy Delegated Act is elevating the

54、 need for digitalization.The manufacturing sector recognizes this along with increasing pressure from consumers to incorporate sustainability and ESG considerations into operations as 95%of respondents reported the existence of policies or programs,whether formal or informal.Companies with higher re

55、venues are more likely to have formalized ESG or sustainability programs(86%)compared to their counterparts in the medium revenue(80%)or low revenue(68%)brackets,but trends indicate the increase in regulations and requirements from upstream and downstream suppliers will put pressure on all manufactu

56、rers,particularly when considering reporting demands around scope 1,2,and 3 emissions.Q.Which of the following best describes your organizations current efforts around ESG(Environmental,Social,and Governance)/Sustainability?Select oneBase:1353We have informal programs in place but not an official st

57、ance18%5%We do not have any ESG/sustainability policies in placeSome of our locations have a formal ESG or sustainability program37%We have a formal company-wide ESG or sustainability policy in place40%SUSTAINABILITY MOVES INTO THE MAINSTREAM SECTION 1:THE CURRENT STATE OF SMART MANUFACTURING“By 202

58、6,Regulations and Sustainability-Linked Lending Will Drive Over 60%of Global Manufacturers to Adopt Product Carbon Footprint as a Key Metric to Operationalize Sustainability Beyond Reporting.”IDC FutureScape Worldwide Manufacturing 2023 Predictions,doc#US48630122,October 2022.118th Annual State of S

59、mart Manufacturing Report 39%Already use some components of smart manufacturing35%Actively evaluating smart manufacturing solutions with the intention to invest13%Do not currently use smart manufacturing technology but there is interest to use it3%Do not currently use smart manufacturing technology

60、and does not plan to10%Already uses a fully integrated smart manufacturing solutionSMART MANUFACTURING ADOPTED GLOBALLY Base:1353Eighty-four percent of respondents have adopted smart manufacturing or are actively evaluating solutions with the intention to invest in the coming year.Companies with hig

61、her revenues are more likely to have adopted smart manufacturing technology,with a 58%adoption rate among respondents in the top third for revenue,compared to 40%among the lower revenue bracket.This may indicate an opportunity for small and mid-size organizations to leverage an incremental,lower ini

62、tial cost and resource approach to smart manufacturing with modular solutions that provide strong value and quick time to payback and ROI.Adoption rates also vary by country,with the top three being China(70%),the US(60%)and India(57%).Q.To what extent has your organization adopted smart manufacturi

63、ng technology?Select oneSECTION 1:THE CURRENT STATE OF SMART MANUFACTURING128th Annual State of Smart Manufacturing Report“Smart manufacturing initiatives are changing the focus of manufacturers from internally focused,plant-specific functionality to more end-to-end solutions,changing MES from plant

64、 monitoring to a key data and intelligence source for the enterprise and supply chain.”Gartner,Critical Capabilities for Manufacturing Execution Systems,May 31,2022.Production Monitoring provides seamless connectivity to machines on the plant floor,delivering transparent,real-time operational KPIs l

65、ike OEE and dashboards to drive continuous improvements.Distributed Control Systems(DCS)use decentralized elements to control dispersed systems,such as automated industrial processes or large-scale infrastructure systems.Supply Chain Planning(SCP)combines data from multiple departments across the bu

66、siness or from outside market resources to sync demand and supply forecasting to improve inventory accuracy and production management.Enterprise Resource Planning(ERP)automates front-and back-office processes,including financial management,revenue management,human capital,order management,billing,an

67、d inventory.Analytics that use data to solve manufacturing bottlenecks,optimize output and quality,and provide new insights.Smart devices are self and system-aware assets that acquire and process operating data and monitor and report on asset conditions such as self-diagnostics and energy usage.Manu

68、facturing Execution Systems(MES)track and document the transformation of raw materials into finished goods,providing real-time production management to drive enterprise-wide compliance,quality,and efficiency.Quality Management Systems(QMS)standardize and automate quality documentation,processes,and

69、measurements.Computerized Maintenance Management Systems(CMMS)help organizations track and manage maintenance and repair activities for their facilities,equipment,and other assets in one place.Asset Performance Management(APM)combines process,operational,and machine-level data through dashboards to

70、monitor machine and plant health,ensuring optimal uptime,throughput,and maintenance needs.SECTION 1:THE CURRENT STATE OF SMART MANUFACTURINGSMART MANUFACTURING SOLUTIONS138th Annual State of Smart Manufacturing Report MANUFACTURERS BIGGEST CHALLENGES As the world righted itself from the sweeping imp

71、act of the COVID-19 pandemic,new issues surfaced in the form of economic uncertainty and continued supply chain disruption.Considering this,our participants identified maximizing data,generating ROI from technology investment,tackling workforce shortages,and minimizing risks to supply chain,quality,

72、and cybersecurity as their most pressing challenges.SECTION 2:148th Annual State of Smart Manufacturing Report There is a growing sense that manufacturers who can attract,retain,and upskill the right team will outperform their competitors.In last years survey,just 35%of respondents reported that the

73、ir organization lacked the skilled workforce to outpace the competition over the next 12 months.That figure has leapt to 46%-and represents the top concern for manufacturers in relation to competitiveness.COMPETITIVE DIFFERENTIATORS FOR MANUFACTURERS IN 2023Q.Please read the statement below and sele

74、ct the top 5 answer options that apply to your organization“My organization lacks the _ to outpace the competition over the next 12 months.”Select top 5 Base:1353/3212022202146%43%39%38%35%34%31%30%25%35%26%32%24%25%21%20%19%15%Skilled workforceTechnologyInnovation SpeedAbility to use data to make d

75、ecisionsProduction CapacityProduction QualityAccess to dataCapitalSECTION 2:MANUFACTURERS BIGGEST CHALLENGES46%of manufacturers say that they lack the skilled workforce to outpace the competition over the next 12 months158th Annual State of Smart Manufacturing Report Base:1353Q.Which of the followin

76、g are the top 5 biggest leadership obstacle(s)your organization faces in the next 12 months?Select top 5The biggest leadership challenge facing manufacturers in the next 12 months is effectively managing people and resources.Understanding how to manage next-generation workers is also a pressing conc

77、ern,ranking third on the list of leadership obstacles.LEADERSHIP AND THE MODERN WORKFORCESECTION 2:MANUFACTURERS BIGGEST CHALLENGESBiggest Leadership ObstaclesBiggest Workforce-Related Obstacles Q.Which of the following are the biggest workforce-related obstacle(s)your organization faces in the next

78、 12 months?Select top 5 Base:1353Training current employees on updated processes41%Change management(getting all employees/departments to effectively use new technology/processes)41%Rising cost of labor/skilled staff 40%Employee engagement(feeling purpose/value in their role)39%Employee retention38%

79、Difficulty finding employees38%Effectively managing people and resourcesLeadership siloed by departments(ineffective communication)Assessing business need and technology/talent fit (including digital transformation)Access to useful data to make effective decisions in real-timeUnderstanding how to ma

80、nage the next generation workersIdentifying and implementing new technologies168th Annual State of Smart Manufacturing Report Already adoptedPlan to adoptProduction MonitoringQuality Management System(QMS)Enterprise Resource Planning (ERP)Supply Chain Planning(SCP)Industrial IoT(IIoT)Manufacturing E

81、xecution System(MES)Advanced AnalyticsEnterprise Asset Management(EAM)Computerized Maintenance Management System(CMMS)Asset Performance Management(APM)31%35%34%38%36%38%39%38%39%42%54%51%49%46%42%41%39%39%38%34%Q.Which of the following smart manufacturing initiatives/systems has your company adopted

82、 or plans to adopt?Select one per row Achieving profitable growth while maintaining quality is one of the most pressing concerns facing manufacturers today.Many are turning to technology to solve their production challenges,in order to gain efficiency while ensuring quality.Of those who have already

83、 adopted some elements of smart manufacturing,the top two systems were production monitoring(54%)and quality management systems(QMS)(51%).Only 10%of respondents havent yet adopted,and dont plan to adopt,a QMS.Overall,this chart shows that there is demand and growth in technology across all software

84、solutions.INCREASING QUALITY AND PROFITABLE GROWTH SECTION 2:MANUFACTURERS BIGGEST CHALLENGESBase:1353178th Annual State of Smart Manufacturing Report Last year,the driving factors for pursuing sustainability and ESG policies were fostering a collaborative environment and addressing social inequalit

85、ies.Over the last year,manufacturers priorities evolved,and the top reason cited was to improve efficiencies,a trend which suggests sustainability is now recognized for its operational improvement capabilities and impact on the bottom line along with the positive social impact.A SWITCH IN SUSTAINABI

86、LITY FOCUS Base:1279Q.Which of the following drives or motivates your organization to pursue ESG/sustainability?Select all that apply *Base note:Asked to those with at least an informal ESG program.Fosters a collaborative environment35%SECTION 2:MANUFACTURERS BIGGEST CHALLENGESImprove efficiencies 4

87、2%A competitive differentiator(to win business from customers who have supplier requirements)41%To address potential environmental issues before they arise38%To build our presence in the community35%Its good for the bottom line 32%To address social inequalities that may suppress talent in the workfo

88、rce30%Pressure from investors23%188th Annual State of Smart Manufacturing Report Base:1341Q.Which of these obstacles have your current smart manufacturing initiatives helped to mitigate?Select all that apply*Base note:Asked to those who have already adopted or plan to adopt smart manufacturing initi

89、ativesManufacturing had the highest average ransom payments in 2022 at$2M1.Protecting against threats is a constant battle,with the potential for enormous damage in terms of supply chain disruption,safety risks,reputational hit and financial losses.Respondents called out this pressing concern by ran

90、king cybersecurity risks as the top obstacle that smart manufacturing initiatives help to mitigate.CYBERSECURITY AWARENESS AND PREPAREDNESS SECTION 2:MANUFACTURERS BIGGEST CHALLENGES“The ransom sums are just part of the story,and the impact of ransomware ranges much more widely than just the encrypt

91、ed databases and devices.90%of those hit by ransomware in the last year said the most significant attack impacted their ability to operate.Furthermore,among private sector organizations,86%said it caused them to lose business/revenue.”Sophos The State of Ransomware 20221Impact of COVID-19 pandemicDe

92、ploying and integrating new technology Product quality/Balancing quality and growthInflationShortage of skilled workersAdapting to new regulations and standards Supply chain disruptionLowering carbon emissionsKeeping pace with market transformationsCybersecurity risks(e.g.,ransomware,phishing)29%28%

93、27%26%26%26%26%25%22%21%198th Annual State of Smart Manufacturing Report INVESTING IN THE RIGHT TOOLS AND TECHNOLOGYOur survey found that 23%of the operating budget is spent on technology,though this investment varies across industries.Whatever the investment level,budgets must be set with an eye fi

94、rmly on the future.Manufacturers will need to invest in areas that help to address the skills shortage,while increasing automation,machine learning,and artificial intelligence,in order to fully exploit the potential of technology and insights across the organization.Differences emerge when we break

95、the results down by industry.Highly regulated manufacturers invest around 2x as much of their operating budget in technology(34%)vs.those in the Packaging(18%)and Metals/Metal Fabricators/Precision Metalforming(18%)sectors.Yet some of the lower invested industries are very margin-challenged and need

96、 to squeeze every type of cost out of their business.Smart manufacturing can help.SECTION 2:MANUFACTURERS BIGGEST CHALLENGESHome and Personal CareFood and BeverageLife Sciences Pharmaceuticals and Medical DevicesSemiconductorIndustrial MachineryPlastics/Rubber ManufacturingAuto,Auto Tier Supplies,EV

97、Electronics25%22%21%25%Metals/Metal Fabricators/Precision Metalforming18%18%20%24%20%19%19%23%AerospaceIndustryMean%of operating34%Material HandlingPulp and PaperPackagingBase:1353Q.What percentage of your operating budget goes towards technology investment?Select onePercent of Operating Budget Inve

98、sted in Technology23%of operating budget is spent on technology.208th Annual State of Smart Manufacturing Report Base:1353Q.Which of the following are the biggest internal obstacle(s)to your organizations current growth for calendar year 2022?Select top 5OVERCOMING TECHNOLOGY PARALYSIS For many resp

99、ondents,the range of available systems and platforms is leading to technology paralysis an inability to decide between solutions.An organization which finds itself held back from investing in technology due to this type of decision paralysis is likely to see an impact on its ability to compete.Conce

100、rn around this area is growing,with a:SECTION 2:MANUFACTURERS BIGGEST CHALLENGESTechnology Paralysis is Increasing24%30%2022202365%year-on-year increase in the number of participants reporting that their organization lacks the technology to outpace the competition over the next twelve months.218th A

101、nnual State of Smart Manufacturing Report THE FUTURE OF SMART MANUFACTURINGAs we look ahead to the future,key trends begin to emerge.Manufacturers are investing in cloud,smart manufacturing solutions,and other technologies to mitigate internal and external risks and to gain a competitive advantage.S

102、ECTION 3:228th Annual State of Smart Manufacturing Report Q.Overall,how important do you think smart manufacturing is to the future success of your organization?Select one Q.When does your organization plan to adopt smart manufacturing?Select oneBase:1353Base:700Within the next 6 months15%I dont kno

103、w/UnsureMore than 2 years from now8%8%Within the next 1 to 2 years39%Within the next 7 to 11 months30%*Base note:Asked to those who are yet to adopt smart manufacturing or are considering adopting it.We saw earlier in this report that adoption rates for smart manufacturing are strong globally.With m

104、anufacturers able to see the benefits in relation to efficiency,ROI,workforce management,and sustainability,its not surprising that this innovation is seen as pivotal.This acknowledgement of its importance is highlighted in planned adoption timelines among those not yet using it.Of the respondents y

105、et to adopt smart manufacturing,45%of them plan to be using the technology within the next year and another 39%plan for the next 1-2 years.SMART MANUFACTURING HOLDS THE KEY TO FUTURE SUCCESS SECTION 3:THE FUTURE OF SMART MANUFACTURING7%29%37%21%5%1%Its a necessity to stay competitiveVery ImportantMo

106、derately ImportantSlightly ImportantNot at all Important238th Annual State of Smart Manufacturing Report Extremely ImportantOut of the technologies invested in over the last year,33%say that Process Automation has had the biggest ROI.Base:1295Base:1353Q.Which of these technologies that your company

107、has invested in had the biggest ROI over the last 12 months?Select top 5*Base note:Options masked through those selected already invested in Q11.TOP INVESTMENTS:CLOUD/SAAS AND PROCESS AUTOMATION Q.Which of the following technologies has your company invested in/plans to invest in(2022/2023)?Select o

108、ne per row58%53%55%52%52%47%47%44%44%43%43%43%41%41%63%Cloud/SaaS63%Process AutomationMachine IntegrationMachine Learning/Artificial IntelligenceIndustrial Internet of Things(IIoT)/Internet of Things(IoT)Cameras/Scanners/Drones5GRPA(Robotic Process Automation)Automated mobile robots and automated gu

109、ided vehicles3D printers/additive manufacturingWearablesGenerative DesignAugmented Reality,Mixed Reality,Virtual RealitySensors/RFID/GeoTaggingBlockchainVoice Recognition/Natural Language Processing(NLP)technologyCobots(Collaborative Robots)Facial RecognitionDigital twins(i.e.,digital replicas synch

110、ronized with physical assets)40%39%38%Already InvestedOur study reveals that the two most popular technology investments process automation and cloud/SaaS,adopted by 63%of participants are delivering the highest returns.Process automation has delivered the biggest ROI,then cloud/SaaS,followed by Ind

111、ustrial Internet of things(IIoT).33%30%25%24%23%21%18%18%16%15%Process AutomationIndustrial Internet of Things(IIoT)/Internet of Things(IoT)Automated mobile robots and automated guided vehiclesMachine Learning/Artificial IntelligenceAugmented reality,Mixed Reality,Virtual RealityCloud/SaaSMachine In

112、tegrationRPA (Robotic Process Automa-tion)5G3D printers/additive manufac-turingSECTION 3:THE FUTURE OF SMART MANUFACTURING248th Annual State of Smart Manufacturing Report Base:1353Even with the increase in technology and automation,people skills are equally-if not more-in demand.Manufacturers seek e

113、mployees who can adapt to changing requirements and collaborate in teams,as shown by the prioritization of communication and teamwork as the top skills manufacturers want from the next generation of employees.In fact,knowledge of smart technology ranked at#6 behind so-called soft skills,including fl

114、exibility/adaptability(2),employee engagement(3),employee initiative(4),and analytical thinking(5).WORKFORCE OF THE FUTURE Q.Looking forward,how important are the following knowledge and/or skills as your organization recruits its next generation of employees?Select one per row SECTION 3:THE FUTURE

115、OF SMART MANUFACTURING“All participating companies noted the critical nature of soft skills such as communication and collaboration.Even as automation makes some aspects of jobs easier and safer,in many cases,it has actually increased the number of workers or departments that collaborate or delegate

116、,thus placing more importance on workers who can,for example,give and comprehend complex instructions.”The Manufacturing Institute PTC&Rockwell Automation,Future skill needs in manufacturing:a deep dive.Communication/TeamworkKnowledge of Smart TechnologyFlexibility/Adaptability STEMEmployee Engageme

117、ntSkilled TradesEmployee InitiativeMaintenance/Installation/RepairAnalytical ThinkingSustainable Practices75%67%71%63%71%61%68%61%68%60%Respondents deemed each of these as At least very important258th Annual State of Smart Manufacturing Report Base:1353Q.Over the next 12 months,in which of the follo

118、wing technologies does your organization plan to increase investment(s)for manufacturing operations?Select all that applyCloud technology/applications/infrastructureAutomation RPA(Robotic Process Automation)Security/Cybersecurity managementSales&operations planning(S&OP)Business and/or Manufacturing

119、 SoftwareInventory managementSmart/connected tools&equipmentLean manufacturingMaintenance management42%33%39%33%38%32%35%30%35%44%The shift to the cloud continues,as manufacturers reap the benefits it offers including adaptability,security,speed to deployment,ROI,and cost.Over the next 12 months,alm

120、ost half(44%)of respondents are planning to increase investment in cloud technology,applications,or infrastructure.Other key technology investments include automation and security/cybersecurity management.CLOUD CONTINUES TO SOAR“We are in an exciting phase of manufacturing transformation right now.T

121、echnologies that were once considered out-of-reach are now seen as essential.By using advanced technologies and the power of the cloud,manufacturers can accelerate a strong digital foundation.This enables them to easily connect,streamline,and advance their operations to gain unprecedented levels of

122、agility and visibility,particularly during uncertain times.”alayan Arkan Vice President,Global Strategy and Sales Lead,Microsoft CorporationPlanned Areas to Increase Investment SECTION 3:THE FUTURE OF SMART MANUFACTURING268th Annual State of Smart Manufacturing Report Quality is driving the future o

123、f digitalization.This universal prioritization across the responses from 1,353 global manufacturers demonstrates how the industry plans to foster growth despite disrupted supply chains and new regulations,while maintaining agility and top quality products.45%of respondents feel that improving qualit

124、y is creating the need to accelerate digital transformation in their organization.Base:1353Q.What areas will Artificial Intelligence(AI)most impact the manufacturing industry?Select top 5 Quality(closed loop control,in-line quality)AutomationAutonomous(or mostly autonomous)plants/factories More accu

125、rate forecastingSupply ChainPredictive approach to operations and production capacityInventory controlTracking and compliance with sustainability/ESG goals and regulationsMachine health and condition monitoringOptimized output 36%31%33%30%32%30%31%28%28%26%24%31%37%Predictive planning of maintenance

126、Sales forecastingRenewed focus on lean initiatives#1 Accelerant for digital transformation(minimizing costs came in 2nd)#1 Area Impacted by artificial intelligence(automation came in 2nd)#1 Outcome from smart manufacturing adoption(reducing cost came in 2nd)Quality topped the responses in several ca

127、tegories,including:QUALITY IS DRIVING DIGITAL TRANSFORMATION SECTION 3:THE FUTURE OF SMART MANUFACTURINGTop Areas Impacted by Artificial Intelligence278th Annual State of Smart Manufacturing Report Base:1279Q.What matters most to your organizations ESG/sustainability program?Select top 5 *Base note:

128、Asked to those with at least an informal ESG program.Product quality/safetyReducing manufacturing wasteRecyclingHealth and SafetyEnergy management(may include technology investments or work with utility companies)Supply chain standards(Supplier selection criteria/Raw material sourcing)Commitment to

129、eco-friendly processes throughout the product lifecycleCarbon offsetting/carbon neutralFulfilling supplier/customer/partner requirements and standardsDiversity,equity,and inclusion 30%30%29%28%27%27%27%25%32%34%The drive to maintain quality,seen elsewhere in this report,surfaced again when we asked

130、participants about sustainability and ESG.Product quality or safety is the most important element in ESG and sustainability programs,followed by reducing manufacturing waste and recycling.All of the responses revealed the growing attention on the“circular economy,”which is based on eliminating waste

131、 and pollution by designing products and processes to maximize efficiencies and extend product life with a particular focus on repair and reuse.QUALITY MATTERS MOST IN SUSTAINABILITY“A recent survey by Gartner,Inc.found that 74%of supply chain leaders expect profits to increase between now and 2025

132、as a result of applying circular economy principles.On average,supply chain organizations have been applying circular economy principles for three years to approximately 16%of their product portfolio.”Gartner Press Release Survey Shows 74%of Supply Chain Leaders Expect Circular Economy to Increase P

133、rofits Through 2025,Sept,28,2022.SECTION 3:THE FUTURE OF SMART MANUFACTURING288th Annual State of Smart Manufacturing Report This survey shows that a third of data goes unused.Many manufacturers see that increased technology adoption creates vast amounts of data,which can be harnessed and analyzed t

134、o improve performance and increase profits.Respondents stated a need for better data and analytics usage to drive positive business outcomes over the next five years,citing this as a competitive shortfall;40%more manufacturers say they lack the ability to use data to make decisions to outpace the co

135、mpetition in 2023 compared to last year.DATA:UNLOCKING A COMPETITIVE OPPORTUNITY Base:1353Q.How do you plan to drive positive business outcomes over the next five years?Select top 5 Increased automation Better use of data analyticsAdopting smart manufacturing softwareAdopting cloud technologyAutomat

136、ed process enforcementESG/sustainability program/policiesIncreased training and employee programsIncreased use of Artificial Intelligence/Machine LearningAdopting supply chain planning softwareLeveraging new/emerging market opportunities36%35%33%32%32%31%31%36%40%40%SECTION 3:THE FUTURE OF SMART MAN

137、UFACTURINGDriving Improvements Over the Next 5 Years298th Annual State of Smart Manufacturing Report“The rapid advancement of technology,especially that of artificial intelligence and machine learning,is arguably at the center of all megatrends.”BlackRock Megatrends:A research study looking at struc

138、tural shifts in the global economy and how they affect our investment thinking Base:1353Q.Which of the following connected devices does your organization employ in its manufacturing operations today?Select all that apply Industrial hardened devices(e.g.,handheld scanners,tablets)42%Consumer devices(

139、e.g.,mobile phones)39%Optical quality scanners(i.e.,vision systems)36%Sensors 37%Cameras/Scanners/Drones38%Automated mobile robots and automated guided vehicles35%Smart thermostats or lighting controls33%RFID scannersAugmented Reality,Mixed Reality,Virtual Reality Wearables28%25%25%Choice IP-enabled

140、 tools and machines(e.g.,callipers)32%Bluetooth devices(e.g.,iBeacons)33%Edge gateways19%SECTION 3:THE FUTURE OF SMART MANUFACTURINGTHE FUTURE OF MANUFACTURING TECHNOLOGYAs manufacturers continue to digitize their operations,more are using connected devices to enhance operations.Below are some of th

141、e once thought over-hyped technologies that are gaining mainstream adoption today.308th Annual State of Smart Manufacturing Report TAKING ACTION Smart manufacturing and the complementary hardware and software mentioned in this report,enable manufacturers to stay competitive,increase agility,and unlo

142、ck long-term opportunities by connecting and automating business.Use the information in this report to help your business and your people plan your technology adoption roadmap regardless of where you are currently in the process.SECTION 4:318th Annual State of Smart Manufacturing Report 1.Identify k

143、ey stakeholders,take action,and agree on your greatest need Gather the people connected to this change both decision-makers and system users.Diverse perspectives clarify the solutions needed,whether disconnected systems,people,processes,supply chains,unexpected downtime,poor quality,lack of visibili

144、ty,control,and/or something else Key Questions To Answer:Where are your information gaps?Have you assembled the key stakeholders?What are the operational challenges youre trying to solve?2.Build the business case for investment Develop your business case by highlighting increased control,efficiency,

145、and savings gained.Gather requirements and include the importance of adaptability,security,and risk mitigation.Key Questions To Answer:What ROI is expected in terms of core outcomes relevant to your business KPIs?What risks should be considered and mitigated?Which use cases offer the right balance o

146、f value creation and time-to-value?3.Research and select your solution(s)Do the work.There are many solutions available,and it is important to do your research.Narrow your potential solutions and review the following questions with the key stakeholders.Key Questions To Answer:Does the solution meet

147、your requirements and business objectives?Will it deliver the ROI that you outlined in your business case?Will it be able to support you in the future?4.Design and deploy the solution(s)Select an implementation partner and create the map that you will follow for a successful process.Once created and

148、 agreed on by your key stakeholders,begin deployment.Key Questions To Answer:Does the design fit your needs?Is there a timeline and achievable ROI?Have the key stakeholders reviewed and agreed on the plan?5.Manage change,measure results,and drive adoptionTo effectively integrate the change that smar

149、t manufacturing will bring into your culture,you will need sponsorship,messaging,measurements,and accountability.Key Questions To Answer:Who will be your adoption champion(s)?What measurements will you use to gauge success?How will you adapt your culture through change management?IDENTIFYBUILDRESEAR

150、CHDESIGNMANAGE key stakeholders,take action,and agree on your greatest need the business case for investment and select your solution(s)and deploy the solution(s)change,measure results,and drive adoptionTo achieve positive,enduring change,be thoughtful about your approach.Set and track goals for con

151、tinuous improvement and decide how you will best measure adoption and the impact of the change.Each organization is different,and the points laid out here will help to ask the right questions in pursuit of answers that will guide your mission.GETTING STARTED GUIDE STEPS SECTION 4:TAKING ACTION328th

152、Annual State of Smart Manufacturing Report 1.IDENTIFY KEY STAKEHOLDERS and agree on your greatest need.2.ESTABLISH EFFECTIVE GOVERNANCE with key stakeholders.3.MAKE THE BUSINESS CASE FOR INVESTMENT by aligning technology,strategy,and metrics/KPIs.4.CREATE A COMMUNICATIONS PLAN that will sustain the

153、vision for future desired outcomes.5.ASSESS YOUR CURRENT CAPABILITIES,risks,and opportunities;benchmark yourself against your competitors.6.RESEARCH and select your solution(s),its not just about the solution but the solution provider.Do you have a strong partner you can count on?7.DESIGN AND DEPLOY

154、 the solution(s).8.PRIORITIZE CHANGES THAT ADDRESS THE PROBLEM(S)you are solving,have the best ROI,and/or eliminate the most risk.9.ESTABLISH AND IMPLEMENT AN ORGANIZATIONAL CHANGE management program and drive adoption.10.ADOPT A CONTINUOUS IMPROVEMENT mindset,establish success metrics and constantl

155、y measure,and provide messaging that highlights what youve learned,what can be more efficient,and how people drive change.SECTION 4:TAKING ACTIONTEN STEPS TO TECHNOLOGYADOPTION(CHECKLIST)338th Annual State of Smart Manufacturing Report SECTION 5:DEMOGRAPHICS/FIRMOGRAPHICS348th Annual State of Smart

156、Manufacturing Report SECTION 5:DEMOGRAPHICS AND FIRMOGRAPHICSDEMOGRAPHICS AND FIRMOGRAPHICSQ.What is your annual business revenue?(US Dollars)Select oneQ.What industry do you work in?Select oneBase:1353Base:1353Annual Revenue(US Dollars)Industrial MachineryElectronicsLife Sciences Pharmaceuticals an

157、d Medical DevicesHome and Personal CareMetals/Metal Fabricators/Precision MetalformingFood and BeveragePlastics/Rubber ManufacturingAerospaceMaterial Handling3%SemiconductorPackagingPulp&Paper3%2%1%10%9%8%6%5%4%Auto,Auto Tier Supplies,EV15%18%18%Industry30%$10 million-$149 million25%$150 million-$49

158、9 million20%$500 million-$999 million18%$1 billion-$10 billion7%$10 billion+358th Annual State of Smart Manufacturing Report SECTION 5:DEMOGRAPHICS AND FIRMOGRAPHICSQ.Which of the following best describes your job position/seniority?Select oneQ.In which of the following departments/functions do you

159、work?Select oneBase:1353Base:1353Seniority/Job LevelDepartment/Job Function40%39%2%6%13%18%13%11%9%5%3%23%18%ManagerITOtherVice PresidentC-SuiteManufacturingOperationsEngineeringSupply chain(including Logistics and Shipping)QualityFacilities/MaintenanceDirectorHead ofDepartmentDEMOGRAPHICS AND FIRMO

160、GRAPHICS368th Annual State of Smart Manufacturing Report SECTION 5:DEMOGRAPHICS AND FIRMOGRAPHICSDEMOGRAPHICS AND FIRMOGRAPHICSQ.In which country do you currently work?Select oneBase:1353Worldwide locations we serveUK15%Germany7%France7%Italy6%Spain6%EUROPEChina7%Japan7%Australia6%India6%South Korea

161、6%ASIA-PACIFICUS15%Canada6%Mexico7%AMERICAS28%AMERICAS41%EUROPE31%ASIA-PACIFIC378th Annual State of Smart Manufacturing Report Allen-Bradley and expanding human possibility are trademarks of Rockwell Automation,Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.Publication INFO-BR027B-EN-P March 2023Copyright 2023 Rockwell Automation,Inc.All Rights Reserved.Printed in USA.Connect with