FEATURE News
FROM ADOPTION TO EXECUTION
Rockwell Automation has announced the UK findings of it’s 11th annual State of Smart Manufacturing Report. The global report shows the UK is entering a more disciplined phase of digital transformation, where success is defined by execution, resilience and workforce capability, rather than technology adoption alone
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he report, sponsored by Rockwell Automation, and compiled by Sapio Research, revealed key insights from the feedback of over 1,500 manufacturing leaders in 13 industrial segments globally. It highlights a clear shift in how UK manufacturers are approaching digital transformation. With 87% of organisations now recognising it as essential, compared with the European Average of 84%, and allocating an average of 27% of operating budgets to industrial technology, the UK has moved beyond early-stage adoption and into a phase where digital investment must translate into operational performance. This need for a connected enterprise, with IT and OT systems integrated, is emphasised to leverage the full potential of AI and digital transformation.
Phil Hadfield, UK managing director, Rockwell Automation, says the report outlines three key insights: the shift from pilot to execution, the evolution of smart manufacturing technologies, and the increasing importance of AI.
He said: “The challenge is no longer access to technology, but the ability to embed it into production environments in a way that improves performance, resilience and competitiveness.”
Artificial intelligence sits at the centre of this transition. Nearly half of manufacturers (49%) have already invested in AI, and adoption of generative AI is now widespread. The focus, however, is shifting away from experimentation toward practical use cases that deliver measurable value. Cybersecurity has emerged as the leading AI application, followed closely by quality control and process optimisation, reflecting a growing emphasis on protecting and stabilising increasingly complex production environments. Hadfield confirms cybersecurity is becoming foundational to smart manufacturing, with 97% of UK firms having
8 June 2026 | Automation
The shift from pilot projects to enterprise-wide execution is crucial for achieving scale, reducing costs, and supporting global operations Top: Phil Hadfield
Bottom: Mike Loughran
a plan to invest in cybersecurity. The growing investments in AI, and reliance on connected technologies is reshaping risk. Mike Loughran , Director for the Intelligent Devices business, EMEA North Region, Rockwell Automation, says Cybersecurity is seen as a key return on investment, with companies investing to protect their connected environments and meet consumer requirements.
Almost half of UK manufacturers report experiencing at least one cyberattack in the past year, despite strong levels of investment in cybersecurity. The implication is clear: as digital maturity increases, so too does exposure. Cybersecurity is no longer a supporting function, but a central pillar of industrial strategy.
Loughran also highlights the workforce skills gap as a critical challenge, citing the 98% of respondents who indicated the need for upskilling. Workforce dynamics are becoming a defining factor in how quickly digital transformation can progress. Rising labour costs now affect 40% of manufacturers, while change management challenges have increased significantly year- on-year.
Encouragingly, rather than reducing headcount, organisations are focusing on reskilling and workforce development, with more than a third of employees now engaged in training programmes designed to support digital roles. Loughran says the UK is leading in workforce skills development, with 76% of manufacturers planning AI integration, and 96% addressing workforce skills. This shift is closely linked to the growing importance of AI capability. A clear majority of manufacturers now see AI skills as critical to attracting the next generation of talent,
highlighting a structural change in how industrial workforces are being shaped. Alongside AI, simulation technologies such as digital twins are beginning to move from concept to deployment. While just over a quarter of manufacturers having already implemented these technologies, the vast majority are either investing or planning to do so, signalling strong forward momentum. These tools are enabling organisations to test scenarios, optimise processes and reduce operational risk before making changes on the factory floor. However, the full value of these technologies is being constrained by a more fundamental issue: data. UK manufacturers report using less than half of the operational data they collect effectively, pointing to a persistent gap between data generation and decision-making. Closing this gap is likely to be one of the most important factors in determining future competitiveness. More broadly, UK manufacturing is showing clear signs of maturity. Smart manufacturing technologies are now widely deployed, and adoption is accelerating as organisations focus on scaling what works rather than piloting new tools. Artificial intelligence is increasingly seen as the technology most likely to deliver meaningful operational improvements, reinforcing its central role in the next phase of industrial transformation. Taken together, the findings suggest that UK manufacturing is entering a new phase of digital transformation. The foundations have been laid, investment is established and adoption is widespread. The next challenge is execution – turning digital capability into consistent, scalable performance in a complex industrial landscape.
Rockwell Automation
www.rockwellautomation.com/en-gb/ capabilities/digital-transformation/ state-of-smart-manufacturing
automationmagazine.co.uk
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