Digital Transformation in Manufacturing: A Guide

Unlike basic digitization, which converts analog information to a digital format, digital transformation in manufacturing uses digital technologies to connect systems, automate processes, and use data to make smarter decisions, from the factory floor to the supply chain.

For example, a manufacturer can use connected sensors on equipment to predict maintenance needs, automatically order parts, and adjust production schedules, all in real-time.

Below, we'll explore each of these key drivers in more detail.

Geopolitics and re-shoring

Global supply chain disruptions have highlighted the fragility of relying on a single source of production. Re-shoring operations can increase control and resilience, but it requires a new level of operational agility only possible with a flexible, digitally-powered infrastructure.

Global competition

The global market is more competitive than ever. To outmaneuver rivals, manufacturers must optimize every stage of their operations to reduce costs and increase speed. Digital transformation enables this through real-time visibility and automation.

Complex supply chains

Modern supply chains require centralized, integrated management. Digital solutions can connect disparate systems, providing end-to-end visibility and a single source of truth.

See how Park Industries streamlined complex quoting processes through application modernization.

Shifting customer expectations

Customers now expect personalized products, faster delivery, and a seamless digital experience. Manufacturers must adapt by building flexible production lines and a direct digital connection to their customers. A great example of this is Van Iperen, a global supplier of specialty fertilizers, which builds customer engagement and transportation apps, dramatically improving its service.

ESG regulations and workforce evolution

Regulatory and societal pressure around environmental, social, and governance (ESG) factors is increasing, requiring digital platforms that track and optimize resource consumption. Furthermore, an aging workforce and labor shortages are driving the need for intuitive, digital tools that capture institutional knowledge and empower new workers.

Technology advancements

The rapid advancement of technologies like IoT, AI, and machine learning is the foundation of digital transformation. All offer powerful new ways to optimize production, predict maintenance needs, improve quality control, and gain real-time insights from data.

For example, Mercedes-Benz delivered a new complaints management portal built with a modern app development platform to manage warranty claims more efficiently.

Industry 4.0

Industry 4.0 strategies lead to increased productivity, reduced costs, higher quality products, and the creation of new business models. Integrating technologies like the Internet of Things (IoT), AI, and advanced robotics to create connected, data-driven, and automated production systems enables real-time data collection, mass customization, and more efficient operations.

For example, Bosch built a platform that combines AI and IoT to facilitate human-robot collaboration and reimagine manufacturing efficiency.

• Increased efficiency and productivity: By automating repetitive tasks and providing a centralized view of operations, digital manufacturing solutions allow the workforce to focus on more strategic, high-value tasks.
• Predictive maintenance: Instead of waiting for equipment to fail, manufacturers can use IoT sensors and data analytics to predict when a machine needs maintenance and automatically send alerts. This proactive approach minimizes downtime and reduces repair costs.
• Faster time to market: Digital tools for twinning and simulation streamline the entire product lifecycle, from design to production, allowing manufacturers to respond more quickly to market demands and launch new products ahead of the competition.
• Better quality control: With real-time data collection and analysis, manufacturers can identify and correct quality issues in real time, reducing waste while enhancing product quality.
• Enhanced resilience: In an unpredictable global environment, a digitally transformed enterprise is more adaptable, able to quickly reconfigure supply chains and shift production to respond to crises with agility and minimal downtime.

A low-code approach can help businesses rapidly integrate with and modernize these systems without a complex and expensive overhaul. Low-code development platforms provide a visual-driven development environment and prompts that simplify the development process, allowing teams to build and connect apps and systems faster. This reduces the time and cost associated with IT/OT convergence and empower a wider range of employees to contribute to the digitization of manufacturing.

The digital transformation process for manufacturing

A typical digital transformation process can be broken down into a structured journey that ensures your efforts are strategic and deliver measurable results. This process usually follows six steps:

1. Assessment: Analyze your current operations to identify pain points and opportunities for improvement.
2. Strategy: Develop a roadmap outlining your goals and prioritizing initiatives.
3. Implementation: Begin building and deploying the applications and systems that will drive change.
4. Adoption: Focus on change management and training to ensure your employees embrace the new tools.
5. Optimization: Continuously monitor the performance of your new systems and identify areas for improvement.
6. Review: Periodically review the impact of your transformation to ensure you are meeting your goals.

Platforms like the OutSystems AI-powered low-code platform accelerate this process by enabling rapid application development and seamless integration with your existing IT landscape.

Challenges in digital transformation for manufacturing

In the manufacturing industry, the biggest challenges in embracing digital transformation include:

• Resistance to change: A new system can be met with skepticism from a workforce accustomed to existing processes. This requires clear communication and active training.
• Legacy IT systems: Many manufacturers are burdened by decades-old, siloed systems that are difficult to integrate.
• OT systems: Like legacy IT systems, these are often decades-old, and they were not designed to communicate with IT systems or even each other. Yet they often generate data that can be useful in other processes or their maintenance. One of the biggest hurdles manufacturers must overcome is the integration of these systems with IT.
• Skills gaps: The demand for developers with the right skills often outpaces supply, creating a need for platforms that enable citizen developers and provide a visual interface.
• Cost concerns: The significant upfront investment requires a strong business case that demonstrates a clear return on investment.

How OutSystems empowers the manufacturing industry

Many of the digital transformation challenges in manufacturing can be addressed by using the OutSystems AI-powered low-code platform to build apps and AI agents that improve production yields and mitigate supply chain risk.

OutSystem enables manufacturers to deliver on digital transformation initiatives by rapidly deploying highly intuitive systems of engagement supported by AI agents, IoT applications, and lifecycle management systems. These AI-powered, low-code applications can:

• Simplify and streamline factory floors.
• Increase efficiency and reduce errors.
• Use more machine data better.
• Improve customer and vendor support.
• Optimize product lifecycles.

With OutSystems, digital transformation in manufacturing is less challenging and more rewarding.

Frequently asked questions about digital transformation