A shift is occurring in the global industrial sector as manufacturers move away from small-scale experimentation and focus on deploying capabilities across entire operations, according to Rockwell Automation’s 11th annual “State of Smart Manufacturing” report.
The global survey, which involved more than 1,500 manufacturers across 17 countries, found that manufacturers are no longer debating the merits of adopting digital technologies. Instead, executive focus has shifted to the execution, scaling, and delivery of measurable value from these investments.
This transition marks a significant inflection point for the sector, with fewer organisations operating in temporary pilot phases and a clear majority deploying smart capabilities directly into daily operations, Rockwell explained.
Today, nearly six in 10 manufacturers report that they actively use smart manufacturing technologies to support their day-to-day operations. Meanwhile, only 18% of surveyed organisations remain in the pilot testing phase.
Blake Moret, chairman and CEO of Rockwell Automation, noted that manufacturers are currently facing more complexity and pressure than at any point in the past decade.
“What stands out in this year’s research is not just the challenges, but how leaders are responding – by making digital transformation a core operating priority. The organisations that are seeing results are those that connect technology, people and processes to turn insight into better decisions, stronger performance and greater resilience.”
Currently, 34% of manufacturing operations are augmented by AI, which supports critical factory functions, including quality control, cybersecurity, and process optimisation.
Looking ahead, manufacturers project that more than half of all operations will be supported by AI capabilities by 2030.
At the same time, the study found that increased connectivity has brought heightened security challenges. According to the survey, 46% experienced at least one cyber incident within the past year.
This rising exposure, driven by increasingly connected and autonomous systems, means that secure, integrated IT/OT architectures have become foundational requirements for safely scaling AI and advanced automation.
To view the complete 2026 State of Smart Manufacturing report, visit rockwellautomation.com.
