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《2022年智能制造现状报告》.pdf
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《2022年智能制造现状报告》.pdf
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Participants in a recent global survey of 321
manufacturers communicated the need for
agility, technology adoption, and improved
processes to respond to market adversity.
The 2022 State of Smart Manufacturing Report is the most robust
edition yet. While participants span the globe, the results reflect
general consistency in major factors impacting manufacturers.
This study from Plex Systems, a Rockwell Automation company, in
collaboration with Hanover Research, uncovers the current state of
smart manufacturing, the challenges manufacturers are facing, and
expectations for the future of the industry.
With the findings and recommendations in this report, as well as
the accompanying checklist found on page 41, you can create your
own technology adoption action plan and embrace the future of
smart manufacturing.
SMART MANUFACTURING:
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 time as possible.
MESA International
INTRODUCTION
2
| State of Smart Manufacturing Report
SMART MANUFACTURING
ADOPTION ACCELERATED
BY 50%
Technology and automation are driving
the next generation of manufacturing,
and smart manufacturing adoption will
continue to accelerate in 2022.
Modularization of software, which allows for
incremental technology adoption, is gaining traction
as manufacturers look to become more agile in the
face of adversity.
• Smart manufacturing adoption grew
by 50% year over year.
• Environmental, social, and governance (ESG)
efforts are being more highly prioritized.
• Barriers to entry are lower, leading to a higher
level of adoption and a more attractive ROI.
THE PANDEMIC EXPOSED
3 EVOLVING BUSINESS
CHALLENGES
The 2021 and 2022 State of Smart Manufacturing
Reports made clear that the pandemic exposed
and exacerbated pre-existing conditions that
manufacturers had previously tolerated or used
band-aid solutions to address. Supply chain
management, skilled worker shortages, and
risk mitigation require a new approach.
• Modern supply chain management solutions
need to account for the complexities of today.
• With over 800,000 unfilled manufacturing
roles, a new approach is needed to solve
for the skilled worker shortage.
• Risk mitigation continues to evolve, and it’s
essential to advance with it.
ONCE OVER-HYPED
TECHNOLOGIES ARE SOLVING
TODAY’S PROBLEMS
Technologies that were once viewed as over-hyped
and unlikely to contribute in a meaningful way are
now deemed vital to success. Cloud, industrial
hardened devices, and process automation
are helping companies overcome challenges
with the skilled worker shortage, supply chain
management, and risk mitigation. Additionally,
augmented reality and wearables are gaining
mainstream adoption by helping to quickly
onboard new employees and attract fresh talent.
• 49% of respondents — up nearly 20% year
over year — are using some form of smart
devices (AR, mixed reality, wearables).
• 75% of respondents view technology as a key
solution to address workforce challenges.
• Manufacturing enterprises that present
themselves as tech-forward are more
appealing to prospective employees.
EXECUTIVE SUMMARY
of survey respondents believe smart manufacturing
is a key to their organization’s future success
83%
3
| State of Smart Manufacturing Report
TABLE OF
CONTENTS
Staying Competitive in 2022 and Beyond ....................................................................... 5
SECTION 1: The Current State of Smart Manufacturing .............................................. 6
Industry obstacles and outlook ................................................................................................................................... 7
The acceleration of smart manufacturing adoption ...............................................................................................8
Production monitoring and supply chain planning are critical to operational success ............................ 10
Manufacturers’ strategies for mitigating risk ......................................................................................................... 11
Environmental, social, and governance (ESG) efforts ....................................................................................... 12
SECTION 2: Manufacturing’s Biggest Challenges ......................................................15
Revealing manufacturing’s unaddressed issues ................................................................................................. 16
Obstacles to growth..................................................................................................................................................... 16
Employee and leadership obstacles ...................................................................................................................... 17
Skilled worker shortage limiting ability to compete ............................................................................................ 18
Solving for supply chain planning challenges now and in the future............................................................. 19
Prioritizing security and risk mitigation ................................................................................................................... 20
The pandemic’s enduring impact ............................................................................................................................ 22
Perceived barriers to smart manufacturing adoption ......................................................................................... 23
SECTION 3: The Future of Smart Manufacturing ........................................................25
Keeping priorities aligned for optimal business progress ................................................................................. 26
Addressing the skilled worker shortage with technology and automation ................................................... 27
Mitigate risk with cloud adoption continuity .......................................................................................................... 29
The shortcomings of traditional supply chain solutions .................................................................................... 30
Unlocking the future of manufacturing with technology .................................................................................... 32
Today’s technologies are essential to achieve tomorrow’s potential ............................................................. 34
SECTION 4: Taking Action ..............................................................................................36
Step 1: Identify key stakeholders and agree on your greatest need .............................................................. 37
Step 2: Make the business case for investment .................................................................................................. 38
Step 3: Research and select your solution(s)....................................................................................................... 38
Step 4: Design and deploy the solution(s) ............................................................................................................ 39
Step 5: Manage change and drive adoption ........................................................................................................ 39
Conclusion ..................................................................................................................................................................... 40
10 steps to technology adoption [checklist] ......................................................................................................... 41
What does the future of smart manufacturing look like if the trends from this report continue? ............ 42
Survey Demographics and Firmographics ....................................................................43
TABLE OF CONTENTS
4
| State of Smart Manufacturing Report
STAYING
COMPETITIVE
IN 2022 AND
BEYOND
STAYING COMPETITIVE IN 2022 AND BEYOND
There’s never been a more pivotal time in manufacturing.
The pandemic exposed the depth of challenges
that manufacturers are facing, including supply
chain disruption, skilled worker shortages, and risk
mitigation. Environmental, social, and corporate
governance (ESG) has also emerged as a must-
address component of the business. At the same time,
the combination of data-driven insights, speed, and
automation has never been more accessible. All of this
is accelerating the adoption of smart manufacturing.
Here are a few stats to think about from this report:
• Smart manufacturing adoption rates increased
50% from 2021 to 2022, meaning 2 out of
every 3 manufacturers are currently using some
form of smart manufacturing component.
• Indecision due to an overload of technology investment
options is a leading growth obstacle for the first
time, with over 20% of respondents selecting it.
• While 78% of manufacturers have a supply chain
planning point solution, 38% of respondents
said they plan to invest in supply chain planning,
indicating that their current solution is not enough.
• Over 80% of respondents for both the 2022
State of Smart Manufacturing Report and
NAM’s (National Association of Manufacturers)
Outlook Survey stressed the importance of
attracting and retaining a quality workforce.
The time for action is now. Forward-looking, informed
leaders are making the decisions that will pave
the way to success this year, while also stepping
back to assess where those decisions will lead
the company in five, ten, and fifteen years.
Plex’s annual State of Smart Manufacturing Report
has tracked the most pressing issues over much of the
last decade. The skilled worker shortage, supply chain
disruptions, and risk mitigation show up as key industry-
level growth obstacles every year, but the reasons for each
are ever-evolving. To solve for these problems and other
dynamics yet unknown, technology – specifically smart
manufacturing – is the key. Drivers like the increase in
plant-level data, greater machine and human connectivity,
the growth of Industrial IoT, and the practical use and
affordability of once-hyped technologies are changing
manufacturing and expanding human possibility.
This report will help you benchmark your technology
usage and uncover best practices to help your
organization stay competitive and thrive not just today
or tomorrow, but next year and every year thereafter.
Start your journey today.
Sincerely,
Tea Myers
Vice President and General Manager
Plex Systems, a Rockwell Automation Company
5
| State of Smart Manufacturing Report
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