Scaling the Smart Manufacturing Mountain
September 25, 2025
Rockwell Automation’s Guide to Adopting Smart Manufacturing Tools, Boosting Efficiency & Unifying Systems for a Smooth Digital Transformation Journey
By: Michael Hart, Sr. Director Product Management, Rockwell Automation
Embracing new technology in manufacturing is much like ascending a mountain—it requires strategy, pacing, and the right gear. Rushing ahead without proper support can strain your systems and your people, but with thoughtful planning and timely technology selection, the climb becomes manageable and rewarding.
There are many paths to digital excellence. Integrating new technologies can significantly boost productivity and efficiency, but even the smoothest rollouts can come with hurdles. In Rockwell’s decades of experience working with customers, they have learned the importance of taking a measured approach to change to avoid unnecessary disruption. Here, they will lay out one way to approach digital transformation.
Beginning the Climb: Laying the Foundation
For many manufacturers, an accessible starting point for digital transformation is real-time production monitoring. Production monitoring enhances visibility and empowers your team to manage performance proactively—without overhauling existing workflows.
By consolidating machine and system data into a single dashboard, production monitoring eliminates silos and simplifies decision-making. It equips your team with actionable KPIs and insights from the shop floor to the executive suite.
With minimal investment in time, budget, and effort, real-time monitoring can deliver immediate value—which makes it an ideal first step on your digital journey.
Climbing Higher: Expanding Capabilities
While production monitoring is a strong foundation, it’s just the beginning. To unlock deeper efficiencies, manufacturers can next implement systems that offer broader control and insight across operations.
A modern manufacturing execution system (MES) is a prime example. By automating routine tasks, a MES reduces errors, cuts costs, and improves profitability. It also provides end-to-end visibility, communication, and traceability throughout the production lifecycle.
Pairing MES with a robust enterprise resource planning (ERP) system further enhances operational oversight. ERP tools help streamline compliance, manage risk, and align financial, operational, and IT strategies under one umbrella.
The real power lies in integrating these systems. When MES, ERP, and other tools work together in harmony, manufacturers can experience transformative results.
Reaching the Peak: Unlocking Full Potential
Even with a unified platform, there’s still room to elevate your operations. Today’s smart tools don’t just optimize—they redefine what’s possible.
Plex MES Automation and Orchestration leverages cutting-edge technology to connect machines and deliver unprecedented transparency and control. With intuitive low-code integration, your team can customize workflows and achieve seamless automation across the plant floor.
Gear Up for Your Digital Climb
According to Rockwell’s 10th Annual State of Smart Manufacturing report, many manufacturers feel they are falling behind technologically compared to last year. If you are exploring new solutions but unsure about the path forward, you are not alone.
Whether you’re just beginning your smart manufacturing journey or seeking advanced, integrated solutions, Rockwell Automation would like to help! Check out their case study library to see how they have helped companies just like yours take on projects to advance their digital transformation journey.
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