Manufacturers today sit at a crossroads. On one hand, the volume of production data is exploding, offering unprecedented opportunities to boost productivity, quality, and resilience. On the other hand, too many factories are still weighed down by manual processes that limit their ability to keep up.
The Manufacturing Leadership Council’s latest Future of Manufacturing Project highlights exactly where manufacturers stand today in their digital journey—and where they need to go next. Here are some key takeaways and what they mean for your business.
Manual Data Collection Is Holding Manufacturers Back
The survey reveals that 70% of manufacturers still collect data manually—often with clipboards, spreadsheets, or paper logbooks. This approach is time-consuming, error-prone, and creates delays between what happens on the shop floor and the decisions being made in the boardroom.
The opportunity: By moving to digital data capture systems, manufacturers can ensure that accurate, real-time information flows seamlessly across their operations—providing the foundation for automation, AI, and smarter decisions.
Data Volumes Are Exploding - and Standardisation Is Key
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44% of manufacturers report that their data volumes have at least doubled in the past two years.
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Yet, many still operate with fragmented systems and legacy machines that make data inconsistent.
Encouragingly, more than half expect their data to be standardised by 2030, a critical step if manufacturers are to gain full value from analytics, benchmarking, and digital twins.
The image shows a production manager and operations Manager looking at production data captured by Machine Monitoring.
Analytics Are Moving from Insight to Prediction
Right now, nearly 60% of manufacturers are focused on understanding their operations better, with a view to optimisation. But the big shift coming is toward prediction: while just 30% are already using data to forecast performance, 60% expect predictivity to be a core objective by 2030.
This transition, from reactive fixes to proactive optimisation, will separate the leaders from the laggards.
Decision-Making Must Move Closer to the Frontline
Today, 77% of survey respondents say data-driven decision-making rests with plant leaders and managers, while only 33% empower frontline operators to use data in real time.
That’s a missed opportunity. Operators are the first to spot issues and seize improvement opportunities. Giving them digital tools and insights not only speeds up decisions but also builds a culture of ownership and continuous improvement.
The image shows a machine operator logging a downtime reason using FourJaw.
AI and Real-Time Data Will Transform Operations
The road ahead points to fully connected, intelligent factories where advanced sensors, robust networks, and AI drive decisions in real time. Manufacturers will be able to:
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Detect and solve problems instantly.
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Optimise production schedules automatically.
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Unlock new levels of efficiency and responsiveness.
The survey makes it clear: manufacturers that embrace these technologies early will be positioned to thrive in the next era of industrial evolution.
Summary
The future of manufacturing is digital. While many companies still rely on manual processes, the survey shows clear momentum toward data standardisation, predictive analytics, and real-time decision-making.
The message is simple: the sooner manufacturers begin their digital transformation, the sooner they’ll unlock productivity, agility, and resilience that will define the factories of tomorrow. You can read how manufacturers are embracing our data collection platform here.
Data Source: The Manufacturers Leaders Council's' Future of Manufacturing Project' annual survey.
