The Nexus of AI and Human-Centric Manufacturing

Jan. 27, 2025
Filtering the hype and promise of AI against a deeper understanding of AI-readiness and operational maturity is critical.

Adoption of artificial intelligence (AI) has increased more quickly within manufacturing than sectors such as construction or transport, and its use is quickly becoming more mainstream in our industry. 

In 2025, we will see a shift from fringe usage of AI to adoption in proven areas of value. For example, it’s still the norm for people to make critical decisions in the absence of intelligent guidance from an algorithm.  But the incorporation of AI tech for smart manufacturing requires a holistic approach that integrates various technologies and strategies to enhance efficiency, productivity and human engagement. 

The reality of AI in current manufacturing operations

Many factories still use paper-based for data management, making it difficult for information to be used in a way that drives insights and improvements in a timely manner. Underscoring the prevalence of this paper-based approach, some research indicates that as much as 75% of manufacturing equipment globally remains disconnected to any form of real-time unified management system or analytics platform. 

This “dark” infrastructure highlights a key gap between the current reality and the future vision of AI-ready smart manufacturing.

The true near-term potential of AI lies in its integration with other technologies and processes to create a cohesive and efficient manufacturing environment. However, baseline digital infrastructure and integrated paperless systems are a critical precursor.

This lack of connectivity is also a key driver of the true near-term potential for AI in creating a cohesive and efficient manufacturing environment. For this to occur, however, a baseline digital infrastructure will still be a critical precursor.

In other words, while 2025 may be a breakout year, the journey to widespread AI adoption is expected to take more than a decade, as it requires a considered approach to transformation based on maturity level. 

A key aspect of this maturity assessment involves the evaluation of where people fit into an AI-driven smart manufacturing approach.

Why human efficiency remains critical to smart manufacturing

By digitalizing tasks, going paperless and embedding tribal knowledge in process-driven tools, manufacturers can synchronize machinery, material and people to achieve optimal efficiency. This approach ensures that human workers are supported by technology, augmenting their daily tasks and building detailed information about operations as a whole, to which AI can then be applied. 

Human augmentation versus straightforward automation is a critical aspect of industrial AI implementation, with an important aspect related to how manufacturers can prepare for the next generation to enter the workforce.  According to Citrix, by 2035, many organizations will be run by digital natives: Millennials and Gen Zers that have grown up either adapting alongside the technological boom or being born in the midst of it.

These generations, accustomed to the convenience and efficiency of tools such as ChatGPT in their daily lives, are likely to find traditional manufacturing environments less appealing. They are seeking workplaces where advanced technologies streamline operations, enhance productivity and foster innovation. Without the adoption of AI into industrial processes, manufacturing jobs will continue to be seen as outdated and less attractive, making it harder to attract fresh talent.

That’s why it will be essential for manufacturers to create a technologically advanced and engaging work environment through:

  • Embracing advanced technology: Using the latest generation of digital tech and installing IoT devices connected to unified digital platforms. 
  • Upskilling: Providing training and development opportunities to ensure teams can effectively use these new technologies. BCG reports that only 14% of frontline employees say they have gone through any upskilling related to AI, compared with 44% of leaders. 
  • Fostering career pathways: Offer clear career progression and development opportunities to retain and motivate young workers. 

James Balzary is CEO at TilliT, a SAGE Group company. SAGE is a certified member of the Control System Integrators Association (CSIA). For more information about SAGE Group, visit its profile on the Industrial Automation Exchange.

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