The report, which surveyed 1,560 decision-makers across 17 countries, identifies a widening chasm between initial software deployment and enterprise-wide scaling. Although most facilities operate at least one MES, the lack of connectivity between systems—such as product lifecycle management and quality control—creates a persistent barrier to extracting long-term value. This fragmentation is compounded by rising cybersecurity concerns, with 46% of manufacturers reporting a cyber incident within the past year.
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The MES Maturity Gap: Manufacturers Struggle to Scale Digital Systems
While 93% of manufacturing firms have implemented Manufacturing Execution Systems, the promise of digital transformation remains largely unrealized. A new Rockwell Automation report reveals that just 23% of companies have achieved full integration across their enterprise resource planning and operational technology systems, leaving significant performance gains trapped in silos.
Ambitions for artificial intelligence are further highlighting these infrastructure weaknesses. While manufacturers aim to have 54% of their processes AI-supported by 2030, 43% admit they currently fail to effectively utilize the data required to fuel such tools. Industry experts note that the primary hurdle has shifted from the decision to adopt technology to the technical complexity of unifying disparate sites. Companies like Kumi North America offer a blueprint for this transition, having expanded their use of Plex MES software across U.S. and Canadian facilities to synchronize operations that previously lacked any digital footprint.
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