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Briefing

  • Despite widespread adoption, manufacturers still struggle to fully integrate production management software into their operations—this is the conclusion of a report released by Rockwell Automation on Tuesday.report.
  • Based on Rockwell's survey of 1,560 manufacturing and industrial professionals across 17 countries, 93% of respondents said they run a manufacturing execution system in at least one plant, but only 23% said they have fully deployed it across all sites.
  • These systems, known as MES, are used to monitor, track, record, and control the process of converting raw materials into finished products on the factory floor. Rockwell noted that integrating these fragmented, patchwork systems has become one of the biggest challenges manufacturers currently face.

Deep insights

As companies move beyond the MES deployment stage, about 44% of respondents view integration as the "most important factor in purchasing decisions." The report says integration is also shaping manufacturers' modernization strategies and their path toward broader digital maturity.

"Given that integration is both the top purchasing requirement and the top modernization challenge, companies risk significant value loss if fragmented systems and underutilized data are not addressed," said Lorenzo Veronesi, associate research director at technology advisory firm IDC, in a statement. IDC contributed to this report.

Meanwhile, rapid advances in artificial intelligence andgrowing cybersecurity risksare forcing companies to update their manufacturing systems. By 2030, more than half of manufacturing processes are expected to be AI-enabled, but about 43% of respondents said they are not effectively using the data they collect.

"As AI-enabled processes become the norm rather than the exception, the ability to unify systems and activate data will determine which manufacturers secure a competitive position in the next phase of production," Veronesi said.

Some companies have successfully scaled MES and gained value from their integrated systems. Since its initial deployment in 2008, automotive supplier Kumi North America has expanded Rockwell's Plex smart manufacturing software across its plants in the United States and Canada.

"Before adopting Plex, our operations struggled to stay synchronized, and some plants had no software at all," said Paul Andrews, assistant vice president of systems at Kumi North America, in a statement.

Custom rubber manufacturer Moldtech implemented MES in six months and saw results almost immediately. According to the report, in the first quarter of 2025, Moldtech reduced scrap costs by 50%, improved efficiency by 20%, and saved $25,000 through the new system.

"We wanted a solution that could provide real-time inventory levels, real-time production metrics, and accurate costs," said Edward Halady, president of Moldtech, in a statement. "We now have real-time scrap reporting and can see exactly how scrap impacts month-end profits."

Rockwell recommends seven steps for effectively scaling MES: standardize systems across sites; lead integration from the start; coordinate ownership across functions; turn data into operational insights; build AI-ready operations; embed resilience into systems; and empower employees to work in different ways.

Anthony Murphy, vice president of product management at Rockwell, said in a statement that MES has shifted from production tracking to providing operational insights across quality management, worker productivity, and supply chain forecasting. He added that with increased connectivity, there are more opportunities to leverage AI.

"Winning manufacturers are not doing more than others; they are better at working together," Murphy said.