The manufacturing sector must work with technology in new ways

In 1886, the world’s first functional automobile, the Benz Patent-Motorwagen, was presented. The two-seater with three spoked wheels was designed with a lightweight chassis and a maximum speed of about 16 km/h.

Some 25 Patent-Motorwagen vehicles were built between 1886 and 1893, and their production required critical human skills and intensive manual work. The Benz Patent-Motorwagen was ahead of its time and initiated a revolution that radically transformed production in various industries.

This metamorphosis has led to the current era of Industry 4.0 – the digital transformation of manufacturing – where the integration of intelligent machines, real-time workflows and artificial intelligence has redefined manufacturing operations.

Digital transformation has further accelerated the development of what was previously unthinkable combined factoryWhile the human element remains essential to optimizing workflows, in just over a century manufacturing systems have evolved from entirely artisanal to fully connected factories that deliver unprecedented levels of efficiency, innovation, scalability, and agility.

New Zebra Production Vision Study 92% of surveyed manufacturing leaders agree that digital transformation is a strategic priority for their organizations, and 89% plan to increase their technology investments this year, highlighting its importance.

As we continue to delve deeper into the Industry 4.0 revolution, we see technologies like AI and the Internet of Things (IoT) transforming entire sectors, driving new levels of efficiency. Six in ten (61%) manufacturers in Zebra’s study expect AI to drive growth by 2029, up from 41% in 2024.

This rise in AI, coupled with digital transformation efforts, reflects manufacturers’ desire to leverage new technologies that will improve the transparency and quality of all operations.

The market – and benefits – of digital transformation in the manufacturing sector are large. Recent tests The value of digital transformation in the manufacturing market is estimated to be $367.6 billion in 2024 and reach $876.1 billion by 2029.

The biggest benefits of digital transformation, according to leaders surveyed in Zebra’s study, include optimizing the workforce by increasing productivity through automation, improving throughput to increase revenue, improving flexibility, and streamlining inventory management and material flow.

Digital transformation has revolutionized the entire value chain, from warehousing and distribution to marketing models. It has enabled manufacturers to meet today’s expectations for efficiency, speed and personalization, creating a new chapter in the history of production and trade worldwide.

As a result, the manufacturing sector must constantly evolve and work in new ways with technology. Manufacturers are focusing on training teams and adopting new technologies to create a workforce that is as advanced as the technology they use, agile and ready for ever-changing conditions.

For example, manufacturers in the Zebra study plan to evolve their workforces and implement more digital tools. Solutions mentioned include augmented reality/virtual reality (70%), computer vision (64%), wearables (61%), workforce management software (56%), mobile computers (55%) and tablets (50%).

Similarly, managing and analyzing large data sets is a significant challenge, but is crucial to ensuring efficiency and quality.

Manufacturers surveyed by Zebra indicated that real-time visibility is critical to maintaining quality, yet only 16% say they have real-time visibility into the manufacturing process.

With the goal of increasing visibility and quality, nearly 100% of surveyed decision makers plan to deploy stationary industrial scanners (99%), autonomous mobile robots (99%), machine vision (98%) and RFID technology (97%) by 2029. Implementing these advanced technologies will provide valuable real-time information, significantly improving data-driven decision-making.

These solutions also increase management efficiency, freeing employees from repetitive tasks so they can focus on more meaningful work and helping to ensure the quality of production processes. In this environment, the balance between technological innovation and human development becomes a pillar for building a solid and sustainable business future.

The strategic shift toward automation and expansion on the factory floor is driving several benefits, according to the Zebra Manufacturing Vision Study. Seven in 10 decision makers cite the ability to focus workers on “high-value,” customer-facing tasks to optimize work, while six in 10 cite meeting service-level agreements (SLAs) and greater flexibility in physical space or factory floor space.

The transformation of production is real. But digitalization goes beyond just implementing new technologies. It’s about diving deep into the dynamics of each industry.

A comprehensive understanding will ultimately help identify organizations that will thrive in the long term, setting a transformation process based on vision and innovation.

Digital transformation invites us to lead a revolution that promises a more prosperous and sustainable future. Just as the first car established a new paradigm, today we can work in new ways and embrace change to create a future where innovation is synonymous with shared progress.

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Enrique Herrera is the Chief Manufacturing Officer at Zebra Technologies. With over 15 years of experience in the manufacturing and technology sectors, he is an expert in business transformation solutions, specializing in industrial operations. Herrera is a keynote speaker on topics such as the Industrial Internet of Things (IIoT), Industry 4.0, digital twins, and modern data analytics, and serves as a trusted advisor to large industrial enterprises.