Rockwell Automation releases 10th annual state of smart manufacturing report

Rockwell Automation Inc. released June 3 results of the global study that makes up its 10th annual “State of Smart Manufacturing Report”. Conducted in March 2025, this year’s study surveyed more than 1,500 manufacturers in 17 leading manufacturing countries.

As manufacturers continue to face uncertainty driven by economic shifts, the report highlights how companies are turning to smart manufacturing to manage risks, improve performance, and support their workforces. It also examines adoption of emerging technology, including artificial intelligence (AI), machine learning (ML), and cloud-based systems.

“Today's technology advances are unlocking new opportunities where the combined potential of people and technology will shape our collective future,” says Blake Moret, chairman and CEO of Rockwell Automation. “As this year’s report shows, manufacturers worldwide 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.”

This report analyzed feedback from 1,560 respondents from 17 of top manufacturing countries with roles from management up to the C-suite, and was conducted by Rockwell Automation and Sapio Research. It sampled 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 study’s key global findings include:

81% of manufacturers say external and internal pressures are accelerating digital transformation, with cloud/SaaS, AI, cybersecurity and quality management ranking as the top areas for smart manufacturing technology investments.
95% of manufacturers have invested in or plan to invest in AI/ML during the next five years.
Organizations investing in generative and causal AI increased 12% year-over-year, signaling a maturing approach to advanced technologies beyond experimentation.
Cybersecurity ranks as the second biggest external risk, with 49% of manufacturers planning to use AI for cybersecurity in 2025—up from 40% in 2024.
48% of manufacturers plan to repurpose or hire additional workers due to smart manufacturing investments. Also, 41% are using AI and automation to help close their skills gaps and address labor shortages.
Quality control remains the top AI use case for the second year in a row, with 50% planning to apply AI/ML to support product quality in 2025.

Beyond these data points, the report reflects broader movement in more efficient and adaptive operations. Manufacturers are using smart technologies to strengthen supply chains, accelerate sustainability initiatives and make faster, more informed decisions. There was also a 5% increase in the importance of analytical and AI skills for leaders, showing that talent development and technical innovation must go hand in hand.

Nonetheless, many manufacturers face challenges when implementing AI. Nearly half of this year’s respondents say the ability to apply AI is now an extremely important skill—up from just 10% last year.