Software solutions


A SHIFTING APPROACH TO SET THE NEW INDUSTRIAL BASELINE IN MANUFACTURING


Manufacturing has entered an era where uncertainty is the only constant. Digital systems are exposing hidden inefficiencies, sustainability has become both an operational and financial imperative, and technology is advancing faster than many organisations can absorb. What was once “future thinking” is now the baseline for competitiveness. Smarter factory transformations will require new structures, behaviours and data foundations, along with the willingness to replace legacy processes. To succeed, this will require a fundamental shift in approach as to how products are made, powered and managed during this transitional era, Toby Mankertz, manufacturing industry director at Columbus UK, explains.


T


he UK manufacturing market is forecast to expand 12.0 per cent by 2033, which represents a change in gear for the sector when compared with growth of 8.6 per cent over the past ten years. The industry is entering a decisive transition, driven not by a single breakthrough but by the convergence of data, AI, sustainability, connectivity and workforce capability. The companies who wait for perfect readiness will find themselves perpetually preparing, while smart factories, supported by humans, data and automation working together, will be the real winners in an uncertain future. There are five defining shifts in how business approach data, connected value chains, AI, sustainability and skills - and it is up to manufacturers to master them all to place themselves in a strong competitive position.


SHIFT 1 – THE DATA-DRIVEN PUSH A fully automated factory is only as resilient as the intelligence and data that guide it. The real shift is not towards full replacement, but orchestration. Future systems must support rapid intervention, human oversight and mixed-mode workflows where people and software agents collaborate. Yet currently, 42 per cent of manufacturers report difficulty sharing data between teams and even more struggle to even access internal data across functions. So how can manufacturers address this demand for more actionable data? Smart factories of the future will be those built on standardisation and technology that amplify human judgement. Investment in clean data for instance, will be key to reduce errors, reveal what actually happens during downtime events and prepare the organisation for technology adoptions. While manufacturers that create data governance committees can establish reliability and align stakeholders around a single source of truth so that data drives action and enables faster, more confident decisions-making under pressure.


SHIFT 2 – SCALABILITY AS THE MISSING LINK IN CONNECTED VALUE CHAINS As supply and value chains become fully


28


connected, every product, batch and shipment will generate data that must be collected, structured, understood and shared securely across suppliers, logistics partners, regulators and consumers. In this future, physical goods will behave like digital assets, with every item carrying a digital identity that follows it from raw materials to end-of-life reuse. Scalability will become the new definition of security as billions of data points will need to move reliably and in real time.


Interoperability will be a defining capability to build adaptable value chains. This is where organisations will require systems that can “speak the same data language,” using global standards such as GS1, so information can move securely across suppliers, logistics partners and regulators. Manufacturers that thrive will be those building flexible, scalable systems that allow trusted data to flow through the value chain, enabling them to respond faster, collaborate more effectively and unlock new business models rooted in transparency and shared insight.


SHIFT 3 – GET ON THE RIGHT SIDE OF THE AI DIVIDE


The first wave of AI’s impact will not be in science- fiction factories, but in the administrative backbone of every business. Many organisations simply “put AI on top” of existing ways of working, hoping for faster versions of the same outcome. That creates short-lived experiments, not transformation. The real opportunity lies in re-engineering whole processes around what AI makes possible, rather than digitising yesterday’s logic. In the short term, manufacturers can add intelligence to what already exists, such as using computer vision to spot defects on production lines at speed rather than relying on people watching the line for faults. The longer-term shift is to put intelligence into the machinery that builds everything else. The real advantage will lie with manufacturers whose facilities can be reconfigured to produce new products, from cars to humanoid robots to things we have not yet imagined, without rebuilding from scratch. In this way, factories will become platforms,


not just plants. AI will amplify human capability and help teams see more, test faster and act with confidence as conditions change.


SHIFT 4 – THE GREEN IMPERATIVE Sustainability is becoming a higher priority on the factory floor, no longer number seven on the list where businesses never get round to it. Over the next few years, the real question will be not whether sustainability competes with productivity, but whether leaders are willing to treat it as the next productivity revolution – one where digital tools and data help reveal invisible waste, and where better environmental performance and better economics are finally aligned.


Double-digit reductions are available to most factories in their first year of serious effort, whether in energy, water or materials. For instance, manufacturers can open up opportunities in longer product lifetimes, repair, reuse and remanufacturing – areas that often save more emissions and cost (estimate of $380 billion in material costs to be saved for EU manufacturers in a “transition scenario”) than simple recycling, but are still underused. Lean practices and a culture of continuous improvement will be key in this shift. These methods triumph disciplined problem-solving over the need for special sustainability technology, and can lead to smarter future capex decisions that unlock new value on the factory floor.


SHIFT 5 – BRIDGING THE SKILLS GAP Long-term vacancies in the UK manufacturing sector cost the economy £6bn in lost output each year. An ageing workforce, too few young people entering the workforce and too many women and under-represented groups leaving are three forces


April 2026 Instrumentation Monthly


Page 1  |  Page 2  |  Page 3  |  Page 4  |  Page 5  |  Page 6  |  Page 7  |  Page 8  |  Page 9  |  Page 10  |  Page 11  |  Page 12  |  Page 13  |  Page 14  |  Page 15  |  Page 16  |  Page 17  |  Page 18  |  Page 19  |  Page 20  |  Page 21  |  Page 22  |  Page 23  |  Page 24  |  Page 25  |  Page 26  |  Page 27  |  Page 28  |  Page 29  |  Page 30  |  Page 31  |  Page 32  |  Page 33  |  Page 34  |  Page 35  |  Page 36  |  Page 37  |  Page 38  |  Page 39  |  Page 40  |  Page 41  |  Page 42  |  Page 43  |  Page 44  |  Page 45  |  Page 46  |  Page 47  |  Page 48  |  Page 49  |  Page 50  |  Page 51  |  Page 52  |  Page 53  |  Page 54  |  Page 55  |  Page 56  |  Page 57  |  Page 58  |  Page 59  |  Page 60  |  Page 61  |  Page 62  |  Page 63  |  Page 64  |  Page 65  |  Page 66  |  Page 67  |  Page 68  |  Page 69  |  Page 70  |  Page 71  |  Page 72