A global report, conducted in association with Rockwell Automation and Sapio Research, reveals how the convergence of people and technology is transforming operations and strengthening industrial resilience.
MILWAUKEE—Rockwell Automation, Inc., a company dedicated to industrial automation and digital transformation, recently announced the results of the 10th annual “State of Smart Manufacturing Report.” The global study, fielded in March 2025, surveyed more than 1,500 manufacturers across 17 of the leading manufacturing countries.
As manufacturers continue to face uncertainty driven by economic shifts, the report highlights how companies are turning to smart manufacturing technologies to manage risks, improve performance, and support their workforce. It also examines adoption of emerging technology, including artificial intelligence (AI), machine learning (ML), and cloud-based systems.
“Today’s technology advancements are unlocking new opportunities where the combined potential of people and technology will shape our collective future,” said Blake Moret, chairman and CEO of Rockwell Automation, in a company release. “As this year’s report shows, manufacturers around the world are using smart manufacturing to navigate disruption and create new opportunities for speed and agility. At Rockwell, we believe innovation and resilience go hand in hand. With the right technology and right people, we can simplify complexity and lead with confidence during times of dynamic change.”
Among the key findings of the global study, 81 percent of manufacturers said external and internal pressures are accelerating digital transformation. Cloud/SaaS, AI, cybersecurity, and quality management rank as the top areas of smart manufacturing technology investments, the release stated.
Ninety-five percent of manufacturers reported they have invested in, or plan to invest in, AI/ML over the next five years. Organizations investing in generative and causal AI increased 12 percent year-over-year, signaling a maturing approach to advanced technologies beyond experimentation.
Cybersecurity ranks as the second biggest external risk, with 49 percent of manufacturers planning to use AI for cybersecurity in 2025—up from 40 percent in 2024. Some 48 percent of manufacturers plan to repurpose or hire additional workers due to smart manufacturing investments. Additionally, 41 percent stated they are using AI and automation to help close the skills gap and address labor shortages. Quality control remains the top AI use case for the second year in a row, with 50 percent planning to apply AI/ML to support product quality in 2025, according to the release.
Beyond these data points, the report is said to reflect broader movement towards more efficient and adaptive operations.
“Manufacturers are using smart technologies to strengthen supply chains, accelerate sustainability initiatives, and make faster, more informed decisions,” the release stated. “There has also been a 5 percent rise in the importance of analytical and AI skills for leaders, showing that talent development and technical innovation must go hand in hand.”
Still, many manufacturers face challenges when implementing AI, according to the report. Nearly half of respondents said the ability to apply AI is now an extremely important skill—up from just 10 percent last year.
The report, conducted in association with Rockwell Automation and Sapio Research, analyzed feedback from 1,560 respondents in 17 of the top manufacturing countries. The respondents’ roles ranged from management up to the C-suite. The survey sampled from a range of industries, including consumer packaged goods, food and beverage, automotive, semiconductor, energy, life sciences, and more.
“With a balanced distribution of company sizes with revenues spanning $100 million to over $30 billion, it offers a wide breadth of manufacturing business perspectives,” the release stated.