《2022年智能制造現(xiàn)狀報告》

Respondingtomarketadversitywithagility,improvedprocesses,andtechnologyadoption

7THANNUAL

STATEOFSMARTMANUFACTURING

REPORT

INTRODUCTION

Participantsinarecentglobalsurveyof321

manufacturerscommunicatedtheneedfor

agility,technologyadoption,andimproved

processestorespondtomarketadversity.

The2022StateofSmartManufacturingReportisthemostrobust

editionyet.Whileparticipantsspantheglobe,theresultsreflect

generalconsistencyinmajorfactorsimpactingmanufacturers.

ThisstudyfromPlexSystems,aRockwellAutomationcompany,in

collaborationwithHanoverResearch,uncoversthecurrentstateof

smartmanufacturing,thechallengesmanufacturersarefacing,and

expectationsforthefutureoftheindustry.

Withthefindingsandrecommendationsinthisreport,aswellas

theaccompanyingchecklistfoundon

page41

,youcancreateyour

owntechnologyadoptionactionplanandembracethefutureof

smartmanufacturing.

SMARTMANUFACTURING:

Theintelligent,real-timeorchestrationandoptimizationofbusiness,physical,anddigitalprocesseswithinfactoriesandacrosstheentirevaluechain.Resourcesandprocessesareautomated,integrated,monitored,andcontinuouslyevaluatedbasedonallavailableinformationasclosetorealtimeaspossible.

MESAInternational

|StateofSmartManufacturingReport2

EXECUTIVESUMMARY

ofsurveyrespondentsbelievesmartmanufacturingisakeytotheirorganization’sfuturesuccess

SMARTMANUFACTURING

ADOPTIONACCELERATED

BY50%

Technologyandautomationaredriving

thenextgenerationofmanufacturing,

andsmartmanufacturingadoptionwill

continuetoacceleratein2022.

Modularizationofsoftware,whichallowsforincrementaltechnologyadoption,isgainingtractionasmanufacturerslooktobecomemoreagileinthefaceofadversity.

?Smartmanufacturingadoptiongrewby50%yearoveryear.

?Environmental,social,andgovernance(ESG)effortsarebeingmorehighlyprioritized.

?Barrierstoentryarelower,leadingtoahigherlevelofadoptionandamoreattractiveROI.

THEPANDEMICEXPOSED3EVOLVINGBUSINESSCHALLENGES

The2021and2022StateofSmartManufacturing

Reportsmadeclearthatthepandemicexposedandexacerbatedpre-existingconditionsthatmanufacturershadpreviouslytoleratedorusedband-aidsolutionstoaddress.Supplychainmanagement,skilledworkershortages,andriskmitigationrequireanewapproach.

?Modernsupplychainmanagementsolutionsneedtoaccountforthecomplexitiesoftoday.

?Withover800,000unfilledmanufacturingroles,anewapproachisneededtosolvefortheskilledworkershortage.

?Riskmitigationcontinuestoevolve,andit’sessentialtoadvancewithit.

83%

ONCEOVER-HYPED

TECHNOLOGIESARESOLVING

TODAY’SPROBLEMS

Technologiesthatwereonceviewedasover-hypedandunlikelytocontributeinameaningfulwayarenowdeemedvitaltosuccess.Cloud,industrialhardeneddevices,andprocessautomationarehelpingcompaniesovercomechallengeswiththeskilledworkershortage,supplychainmanagement,andriskmitigation.Additionally,augmentedrealityandwearablesaregainingmainstreamadoptionbyhelpingtoquicklyonboardnewemployeesandattractfreshtalent.

?49%ofrespondents—upnearly20%yearoveryear—areusingsomeformofsmartdevices(AR,mixedreality,wearables).

?75%ofrespondentsviewtechnologyasakeysolutiontoaddressworkforcechallenges.

?Manufacturingenterprisesthatpresentthemselvesastech-forwardaremoreappealingtoprospectiveemployees.

|StateofSmartManufacturingReport3

TABLEOFCONTENTS

TABLEOF

CONTENTS

StayingCompetitivein2022andBeyond

5

SECTION1:TheCurrentStateofSmartManufacturing

6

Industryobstaclesandoutlook

7

Theaccelerationofsmartmanufacturingadoption

8

Productionmonitoringandsupplychainplanningarecriticaltooperationalsuccess

10

Manufacturers’strategiesformitigatingrisk

11

Environmental,social,andgovernance(ESG)efforts

12

SECTION2:Manufacturing’sBiggestChallenges

15

Revealingmanufacturing’sunaddressedissues

16

Obstaclestogrowth

16

Employeeandleadershipobstacles

17

Skilledworkershortagelimitingabilitytocompete

18

Solvingforsupplychainplanningchallengesnowandinthefuture

19

Prioritizingsecurityandriskmitigation

20

Thepandemic’senduringimpact

22

Perceivedbarrierstosmartmanufacturingadoption

23

SECTION3:TheFutureofSmartManufacturing

25

Keepingprioritiesalignedforoptimalbusinessprogress

26

Addressingtheskilledworkershortagewithtechnologyandautomation

27

Mitigateriskwithcloudadoptioncontinuity

29

Theshortcomingsoftraditionalsupplychainsolutions

30

Unlockingthefutureofmanufacturingwithtechnology

32

Today’stechnologiesareessentialtoachievetomorrow’spotential

34

SECTION4:TakingAction

36

Step1:Identifykeystakeholdersandagreeonyourgreatestneed

37

Step2:Makethebusinesscaseforinvestment

38

Step3:Researchandselectyoursolution(s)

38

Step4:Designanddeploythesolution(s)

39

Step5:Managechangeanddriveadoption

39

Conclusion

40

10stepstotechnologyadoption[checklist]

41

Whatdoesthefutureofsmartmanufacturinglooklikeifthetrendsfromthisreportcontinue?

42

SurveyDemographicsandFirmographics

43

|StateofSmartManufacturingReport4

STAYINGCOMPETITIVEIN2022ANDBEYOND

STAYINGCOMPETITIVEIN2022ANDBEYOND

There’sneverbeenamorepivotaltimeinmanufacturing.Thepandemicexposedthedepthofchallenges

thatmanufacturersarefacing,includingsupply

chaindisruption,skilledworkershortages,andriskmitigation.Environmental,social,andcorporategovernance(ESG)hasalsoemergedasamust-addresscomponentofthebusiness.Atthesametime,thecombinationofdata-driveninsights,speed,andautomationhasneverbeenmoreaccessible.Allofthisisacceleratingtheadoptionofsmartmanufacturing.Hereareafewstatstothinkaboutfromthisreport:

?Smartmanufacturingadoptionratesincreased50%from2021to2022,meaning2outofevery3manufacturersarecurrentlyusingsomeformofsmartmanufacturingcomponent.

?Indecisionduetoanoverloadoftechnologyinvestmentoptionsisaleadinggrowthobstacleforthefirst

time,withover20%ofrespondentsselectingit.

?While78%ofmanufacturershaveasupplychainplanningpointsolution,38%ofrespondents

saidtheyplantoinvestinsupplychainplanning,indicatingthattheircurrentsolutionisnotenough.

?Over80%ofrespondentsforboththe2022StateofSmartManufacturingReportandNAM’s(NationalAssociationofManufacturers)OutlookSurveystressedtheimportanceofattractingandretainingaqualityworkforce.

Thetimeforactionisnow.Forward-looking,informedleadersaremakingthedecisionsthatwillpavethewaytosuccessthisyear,whilealsosteppingbacktoassesswherethosedecisionswillleadthecompanyinfive,ten,andfifteenyears.

Plex’sannualStateofSmartManufacturingReporthastrackedthemostpressingissuesovermuchofthelastdecade.Theskilledworkershortage,supplychaindisruptions,andriskmitigationshowupaskeyindustry-levelgrowthobstacleseveryyear,butthereasonsforeachareever-evolving.Tosolvefortheseproblemsandotherdynamicsyetunknown,technology–specificallysmartmanufacturing–isthekey.Driversliketheincreaseinplant-leveldata,greatermachineandhumanconnectivity,thegrowthofIndustrialIoT,andthepracticaluseandaffordabilityofonce-hypedtechnologiesarechangingmanufacturingandexpandinghumanpossibility.

Thisreportwillhelpyoubenchmarkyourtechnologyusageanduncoverbestpracticestohelpyourorganizationstaycompetitiveandthrivenotjusttodayortomorrow,butnextyearandeveryyearthereafter.

Startyourjourneytoday.

Sincerely,

丁essaMye卜s

VicePresidentandGeneralManager

PlexSystems,aRockwellAutomationCompany

|StateofSmartManufacturingReport5

|StateofSmartManufacturingReport6

SECTION1:

THECURRENT

STATEOFSMART

MANUFACTURING

Technologyandautomationarepoweringtheleadersin

today’smanufacturingspacewhiledrivingthenextgeneration

ofmanufacturinginnovation.Thisyear’ssurveyresults

buildonPlex’spreviousreports,reaffirmingthattechnology

adoptioncontinuestoaccelerate,andpreviouslyover-hyped

technologiesarenowsolvingtheindustry’scriticalchallenges.

THECURRENTSTATEOFSMARTMANUFACTURING

INDUSTRYOBSTACLESANDOUTLOOK

It’simpossibletodescribethecurrentstateofmanufacturingwithoutaddressingoneofthebiggestfactorsimpactingtheworld—2020and2021weredefinedbythedevastatingrippleeffectsofCOVID-19.

Thesurveyresultsfromthelasttwoyearsmakethisabundantlyclearthroughtheresponsesthatrankedthepandemicasfarandawaythebiggestobstaclefacingmanufacturers.Butbothsurveysalsomadeclearthatthepandemicexposedand

exacerbatedpre-existingconditions.

Growthobstacles2021Report—occuredduring2022Report—respondent’sview

theworstpartofthepandemicattimeofsurvey(Oct2021)

Securityrisks

Supplychaindisruption

COVID-19

Shortageof

skilledworkers

Q:Whichofthefollowingarethebiggestobstacle(s)toyourorganization’scurrentgrowthasofcalendaryearQ32021?(n=321)

“

performanceindex(RPI)anda27%increaseintheirprofitperformanceindex(PPI),whereasnondigitalmanufacturersexperienceddecreasesof9%inRPIand2%inPPI.

—ReidPaquin

ResearchDirector,IDCManufacturingInsights

IDCTechnologySpotlight,sponsoredbyPlex,TheImportanceofManufacturingAutomationforDigitalTransformation,doc#US48798322,January2022

|StateofSmartManufacturingReport7

THECURRENTSTATEOFSMARTMANUFACTURING

THEACCELERATIONOFSMART

MANUFACTURINGADOPTION

Whileadoptionacceleratedinthewakeofthepandemic,thissurveyshowsthat

itactedasacatalysttoforcedecisionsalongwiththespeedofadoption.

50%

60%

75%

yearoveryearincreaseinsmartmanufacturingadoptionrates

ofallcompaniesarenowusingeitherafullyintegratedsolutionorhavesomecomponentsofsmartmanufacturinginadoption

oforganizationswillhavesomecomponentsofsmartmanufacturinginadoptionbytheendof2022

20212022projected2023

75%

60%

40%

28%

18%

15%

10%

5%

2%2%

40%

5%

NoplansInterestEvaluatingAdoptedorexecuted

Q:Towhatextenthasyourorganizationadoptedsmartmanufacturing?(n=321)

KEYSOLUTIONS

EnterpriseResourcePlanning(ERP)automatesfront-andback-officeprocesses,includingfinancialmanagement,revenuemanagement,humancapital,ordermanagement,billing,andinventory.

ManufacturingExecutionSystem/Suite(MES)tracksanddocumentsthetransformationofrawmaterialsintofinishedgoods,providingreal-timeproductionmanagementtodriveenterprise-widecompliance,quality,andefficiency.

QualityManagementSystem(QMS)standardizesandautomatesqualitydocumentation,processes,andmeasurements.

SupplyChainPlanning(SCP)combinesdatafrommultipledepartmentsacrossthebusinesstosyncdemandandsupplyforecastingtoimproveinventoryaccuracyandproductionmanagement.

ProductionMonitoringprovidesseamlessconnectivitytomachinesontheplantfloor,deliveringtransparent,real-timeoperationalKPIsanddashboardstodrivecontinuousimprovements.

AssetPerformanceManagement(APM)combinesprocess,operational,andmachine-leveldatathroughdashboardstomonitormachineandplanthealth,ensuringoptimaluptime,throughput,andmaintenanceneeds.

MESAutomationandOrchestrationconnectsyourMEStotheplantedgetocontrolinformationflow,processes,andworkcentersetup.

|StateofSmartManufacturingReport8

THECURRENTSTATEOFSMARTMANUFACTURING

Smartmanufacturingadoptiontimelineforthoseinconsideration

12%

Next6

months

32%

Next7–11months

42%

Next1–2years

Q:Whendoesyourorganizationplantoadoptsmartmanufacturing?(n=125)

Adoptioniscoming.Today,28%ofmanufacturersareevaluatingsmarttechnology

adoptionbuthaven’tstartedtheirdigitaltransformationyet.

Smartmanufacturinginitiativesinconsiderationforadoption

EnterpriseResource

Planning(ERP)

QualityManagement

System(QMS)

ManufacturingExecution

System(MES)

IndustrialIoT(IIoT)

ProductionMonitoring

SupplyChain

Planning(SCP)

AdvancedAnalytics

EnterpriseAssetManagement(EAM)

AssetPerformance

Management(APM)

APACleadingthechargeforadoption

Percentageofrespondentsthatareevaluatingadoptionandplantoadoptinthenext7–11months

48%

APAC

20%

NorthAmerica

33%

EMEA

(Asia-Pacific)

(Europe,MiddleEast,andAfrica)

|StateofSmartManufacturingReport9

THECURRENTSTATEOFSMARTMANUFACTURING

PRODUCTIONMONITORINGAND

SUPPLYCHAINPLANNINGARE

CRITICALTOOPERATIONALSUCCESS

Whileallaspectsofsmartmanufacturingaresimilarly

desired,productionmonitoringandsupplychainplanning

tookthetopranksas“missioncriticalcomponents”

thatorganizationsneedtooperatesuccessfully.

Solutionslikethesecanalsobringquicktime-to-valueand

helpsetthestageforamanufacturingexecutionsystem(MES)

and/orenterpriseresourceplanning(ERP)implementation.

Thecurrenttrendofmodularizationoftechnologymakesitpossible

toincrementallyadoptsolutionsandachievevaluequickly.

Asmanufacturerslooktostreamlineprocessesandsolve

today’schallenges,theyplacevalueondemonstrating

thesuccessandfinancialviabilityinliveoperations.

Howdosmartmanufacturingsolutionsrank?

Alot—ItplaysasignificantroleinouroperationsMission-Critical—Ourorganizationcouldnot

successfullyoperatewithoutthis

EnterpriseResourcePlanning

ProductionMonitoring

QualityManagementSystem

SupplyChainPlanning

AssetPerformanceManagement

ManufacturingExecutionSystem

49%19%

42%

24%

21%

44%

40%

22%

46%16%

21%

41%

Q:Overthelastyear,howbigofarolehaseachofthelistedcomponentsofsmartmanufacturingplayedinyourorganization’soperations?(n=321)

|StateofSmartManufacturingReport10

THECURRENTSTATEOFSMARTMANUFACTURING

MANUFACTURERS’STRATEGIES

FORMITIGATINGRISK

Ofthe321manufacturingrespondentsforthissurvey,roughlyhalfreportedthey

areadoptingcloudtechnologiesandmanagingcybersecurityriskstoensure

businesscontinuity.

Manufacturers’strategiesformitigatingrisk

48%

39%

36%

41%

46%

Adoptingcloudtechnologies

Ensuringdata

accuracyforreporting

Developinga

planincase

ofoperational

disruption

Managingcybersecurityrisks

Evaluatingcriticalsuppliers

andinformed

decisionmaking

Q:Howisyourorganizationcurrentlymitigatingrisk?(n=321)

“Tth

“

accessandcontrol,andthebenefitsofcloud-basedsolutionsinnotonlyenablingthenew“workfromanywhere”paradigm,butasafundamentalnext-generationtechnologyenabler.

—Gartner?,CloudComputinginManufacturingIsFoundationalTodayandthe

RequirementtoOperateintheFuture,RickFranzosa,29October2020

GARTNERisaregisteredtrademarkandservicemarkofGartner,Inc.and/oritsaffiliatesintheU.S.andinternationallyandisusedhereinwithpermission.Allrightsreserved.

|StateofSmartManufacturingReport11

THECURRENTSTATEOFSMARTMANUFACTURING

ENVIRONMENTAL,SOCIAL,AND

GOVERNANCE(ESG)EFFORTS

Thisyear’srespondentsoverwhelminglydemonstratetheincreasingfocuson

sustainabilityandESG,motivatedbythedesiretoshowbetterstewardship,community

leadership,andcompetitiveness.

CurrenteffortsaroundESG

97%statedthattheyhaveaformalorinformalpolicyinplace

Wehaveaformal,company-wideESG

orsustainabilitypolicyinplacetoguide

ourinvestmentsandstrategicinitiatives

Someofourlocationshaveaformal

ESGorsustainabilityprogram

Wehaveinformalprogramsin

placebutnotanofficialstance

WedonothaveanyESG/

sustainabilitypoliciesinplace

Idon’tknow

Q:Whichofthefollowingbestdescribesyourorganization’scurrenteffortsaroundESG/sustainability?(n=321)

MotivationforpursuingESG

42%

42%

Toaddresssocialinequalities

Fostersacollaborativeenvironment

41%

41%

Tobuildourpresenceinthecommunity

Toaddresspotentialenvironmentalissues

39%

39%

Acompetitive

differentiator

Adesireto

dogood

Q:Whichofthefollowingdrivesormotivatesyourorganizationtopursue

ESG/sustainability?(n=321)

|StateofSmartManufacturingReport12

THECURRENTSTATEOFSMARTMANUFACTURING

TopprocessesinmanufacturingESG/sustainabilityprograms

47%

Energy

management

42%

Recycling

42%

Commitmentto

“eco-friendly”

processes

42%

Supplierselection

criteria

40%

Carbonoffsetting/

carbonneutral

38%

Waterconservation

31%

Community

investments

OftheitemsincludedinmanufacturerESGprograms,energymanagement,recycling,andcommitmentto“eco-friendly”processesrankedasthetopthreestepsforaction.

Q:Whichofthefollowingareincludedinyourorganization’sESG/sustainabilityprogram?(n=311)

“

waste.Usingourownadvancedautomationtechnology,wereducedpaperjobpacketsforourengineered-to-order(ETO)productsby70%.

—

2021SustainabilityReport,RockwellAutomation

|StateofSmartManufacturingReport13

THECURRENTSTATEOFSMARTMANUFACTURING

SysteminvestmenttosupportESGefforts

100%

90%

42%42%41%38%38%34%31%29%27%3%

80%QualityManufacturingSupplyChainIndustrialEnterpriseProductionAdvancedEnterpriseAssetAssetPerformanceUnsure

ManagementSystem(QMS)

ExecutionSystem(MES)

Planning(SCP)

IoT(IIoT)

ResourcePlanning(ERP)

Monitoring

Analytics

Management

(EAM)

Management

70%

(APM)

60%

50%

40%

30%

20%

10%

0%

Q:Whattechnologieshasyourcompanyinvested/doesyourcompanyplantoinvestinthatyoufeeldirectlysupportyourorganization’sESG/sustainabilityefforts?(n=321)

WhenaskedaboutsystemsforinvestmenttosupporttheseESGefforts,respondentsfocusedheavilyonMES,QMS,andsupplychainplanning.Byusingthesesystems,companiesareabletoaddressmanyoftheirtopESGefforts.Moreefficienttechnology,processes,andplanningenabledbythesesystemsreducewaste

andmaximizeoutput.Thesesystemsalsoenhanceagility,whetheritispivotingtoanewproductlineorprovidingatemporarysocialgood,likeproducingmasksandventilators.Efficiency,adaptability,andaccountabilityarebecomingcoretostakeholdervalue.

|StateofSmartManufacturingReport14

SECTION2:

MANUFACTURING’S

BIGGEST

CHALLENGES

TheCOVID-19pandemichasexposedthedepthoflingering

obstaclesinthemanufacturingindustryandmadeitimpossible

toignorethemanylonger.Ithasalsoexposedthebrittlenatureof

systems,processes,andsupplychainsolutionsthathadhistorically

measuredas“goodenough”untilthetestofglobalchange.

|StateofSmartManufacturingReport15

MANUFACTURING’SBIGGESTCHALLENGES

Shortageofskilledworkers

Impactof

COVID-19

Securityrisks

Supplychaindisruptions

Newregulations

Production

quality

Informational

silos

Technologyparalysis

Competition

Weakdemand

Leadership

Tariffs

REVEALINGMANUFACTURING’S

UNADDRESSEDISSUES

Eachyear,thisreporthasconsistentlyshownsupplychain

disruption,skilledworkershortage,andsecurity/risk

managementasthetopchallengesforbusiness.Nowthe

industryisdealingwithextremesineachoftheseareasalong

withtheuniqueadversitycreatedbyalingeringpandemic.

OBSTACLESTOGROWTH

Tobuildabusinessfitforresiliency,manufacturersmust

identifythesepainpointsinthelight,assessthedegreeof

severity,anddeterminehowbesttosolvetheseproblems.

Withsmartmanufacturinginplace,organizationscanprevent,

address,andsolvemajorbusinesschallengesandgrowth

obstacles,includingunexpectedcomplicationsanddevelopments.

Growthobstaclesforthe

year202220212022

Technologypfirsttimegrow

aralysisrankedathobstacleat2

sa

4%

0%10%20%30%40%50%60%

Q:Whatdoyouseeasthebiggestobstacle(s)toyourorganization’sgrowthnextyear(calendaryear2022)?(n=321)

|StateofSmartManufacturingReport16

MANUFACTURING’SBIGGESTCHALLENGES

Largestleadershipobstacles

40

30

20

10

Difficultyfinding

Increaseddependencyonautomation

Employee

EMPLOYEEANDLEADERSHIPOBSTACLES

Thecurrentworkforceshortage,especiallyforskilledworkers,presentschallengestotoday’smanufacturers.Atechnologicallyadvancedworkplaceisanattractivefeatureforprospectiveemployees,especiallythoseinyoungergenerations.Regardlessofwhatchallengesarise,itwillbedifficult—ifnotimpossible—todevelopacohesive,actionableplanwithoutstrongleadershipandskilledemployees.Whilesmartmanufacturingdoesmanythings,itcannotfunctionoptimallywithoutcontinuity,

accountability,andcommunication—bothhuman-to-humanandhuman-to-machine.Changemanagementisacriticalcomponenttosmartmanufacturingandshouldbekeptattheforefrontwhenmovingtowardsadoption.Asoursurveyidentified,employeeandleadershipobstaclescreateorganizationalchallengesacrosstheboard,regardlessoftechnologyadoption.

100100

90

80

70

60

50

90

80

Largestemployeeobstacles

70

60

50

skilledemployees

Trainingcurrentemployees

Agingworkforce

40

30

20

10

onupdatedprocesses

retention

10

20

30

40

50

60

70

80

90

100

LackofLackofInabilitytokeepupwith

continuity

Lackofaccountabilitycommunicationachangingmarket

10

20

30

40

50

60

70

80

90

100

Q:Whichofthefollowingarethebiggestemployeeobstacle(s)yourorganizationfaces?(n=133)Q:Whichofthefollowingarethebiggestleadershipobstacle(s)yourorganizationfaces?(n=45)

|StateofSmartManufacturingReport17

MANUFACTURING’SBIGGESTCHALLENGES

SKILLEDWORKERSHORTAGE

LIMITINGABILITYTOCOMPETE

Thelackofskilledworkershasbeenacommonthemeineveryeditionofthisreport.Howcanmanufacturersfindandretainthebestemployeesandsupportthemtodevelopintotheleaderstheyneedfortomorrow?

Companiesareaddressingtheskilledworkforceissuebyleveraginginnovation,technology,andtheirabilitytousedatatomakedecisions.Employersthatcanequipemployeeswiththerighttoolswhilealsosupportingthepathforlearninganddevelopmentwillbebestpositionedforthefuture.

Technology

Lackingareasincompetition

Speed

Innovation

Skilledworkers

Abilitytousedatatomakedecisions

Q:Pleasereadthestatementbelowandselecttheansweroptionsthatapplytoyourorganization.“Myorganizationlacksthe_____tooutpacethecompetition.”(n=321)

84%

ofre