2025年智能制造与运营调查报告：实施挑战应对（英文）

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2025/5/1309:192025smartmanufacturingsurveyDeloitteInsights

2025smart

Manufacturingandoperationssurvey:Navigating

chaengesto

impementation

Deloitte'ssurveyof600executivessbowsthatas

factoriesandoperationsgetsmarter;manufacturersworktoovercomeobstaclesintalentacquisition,

managecomplextransformations,andmitigate

operationalrisk

ARTICLE12-MINREAD.01MAY2025

withitsabilitytocaptureandintegratedatafromacrossfacilitiesfueledby

automationandanalytics,smartmanufacturingandoperations(alsocalled"smartfactories")cananswerthemanystubbornchallengesrelatedtocapacityand

competitiveness—eventhoseposedbytoday'smarketvolatility."Industry4.0"hasbeenmakingambitiouspromisesforyears,butthemomentofvaluerealizationisfnallyarriving·

Deloittesurveyed600executivesfromlargemanufacturingcompanieswith

headquartersoroperationsintheunitedstates,fromAugusttoseptember2024

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(seemethodology).withrespondentsfromindustrialproducts,energyand

chemicals,biopharma,automotive,consumerproducts,andothersectors,it'sclearthesmartmanufacturingtideisshifting·

Thesurveyresultsshowthatcompaniesembracingthetrendaremoreagile,moreattractivetotalent,andmoreproductive.Theresultsalsorevealkeychallengesinimplementingsmartmanufacturingsystems,suchasmanagingcomplex

transformationsandmitigatingoperationalrisks.Toovercomethesehurdles,executivesareinvestingincoretechnologiesanddataanalytics,allocating

signifcantresourcestocybersecurityprocessesandcontrols,andfocusingon

workforceupskilling.Additionally,organizationsareformingdedicatedinternalteamstomanagechangeanddriveorganizationaltransformation.

smartmanufacturingandoperationstransformationsarencreasg

Thereiswidespreadandgrowingconfdencethatsmartmanufacturingand

operationswillbeanindispensablefactorinproductivityandenterprisegrowth.Ninety-twopercentofmanufacturerssurveyedsaidtheybelievesmart

manufacturingwillbethemaindriverforcompetitivenessoverthenextthreeyears,asix-percentage-pointincreasefromasurveyweconductedin2019.

similarly,85%ofrespondentsbelievetheirsmartmanufacturinginitiatives

transformhowproductsaremade,improveagility,andattractnewmanufacgtalent.

Theinterestandinvestmentinsmartmanufacturingisfueledbywhat

manufacturersseeasitsprimarybenefts:Almosthalf(49%)。frespondentsreportedoperationalbeneftsastheprimaryvaluesoughtwithsmart

manufacturing,while44%notedfnancialbeneftsasthesecondmost-soughtvalue.

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smartmanufacturing'svalueisemerging

Interestandinvestmentinsmartmanufacturingandoperationsareencouragedbygrowingreturns.Respondentswereaskedwhichbusinessmetricshavebeen

impactedbytheimplementationofsmartmanufacturinginitiatives.Intermsofnetimpactsinceimplementation,respondentssaw,onaverage,a10%to20%

improvementinproductionoutput,a7%to20%improvementinemployee

productivity,and10%to15%inunlockedcapacity.

Respondentscitedimprovementsderivedfromsmartmanufacturinginitiatie

encouragingsimilarinvestmentsinsupportingfunctions.whilerespondentr

theirorganizationsasmostmatureintheareasofqualitymanagement,operations,continuousimprovement,andtechnology,theyreportedrelativelylowmaturityinhumancapitalandmaintenance.BYanalyzingthegapbetweencompanies'currentandaspirationalmaturitylevels,threefunctionsseemripeforinvestment:humancapital,materialmanagement,andmaintenance.

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withgrowingmaturity,investmentisalsoontherise

Lookingahead,manufacturersaretargetinghumancapitalforthelargest

improvement,withaspirationsforinformationtechnology,datacapture,analytics,andapplicationdevelopmcentinfrastructurematurityclosebehind.AStriking78%ofrespondentsallocatemorethan20%oftheiroverallimprovementbudget

towardsmartmanufacturinginitiatives.Eighty-eightpercentexpectinvestme

continueorincreaseinthenextfscalyear.Asexpected,thescaleofinvestment

roughlytrackswithenterprisesize,withsmallercompaniesinvestingmodestlyandmuchlargercompaniesinvestinganorderofmagnitudemore.

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Howareorganizationsinvestinginsmartmanfacturng?

Adopting,connecting,andoptimizingtechnologies(suchassensors,edgeandcloudcomputingpower,cybersecurity,andanalytics)clearsthewayfor

manufacturerstomovefartherandfasterdowntheroadtosmartmanufactu

operations.Thefocustodayisonestablishingthesmartmanufacturingtechngyanddatafoundations.Manufacturerinvestmentspaintapictureoftheirpriorities.

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Doinvestmentsinautomationsignalaresponsetotalentshortages?

Intermsofpriorityfocusareasforinvestmentwithinthenexttwoyears,almosthalf(46%)。frespondentsrankedprocessautomationasthefrstorsecond

priority.ASomewhatsmallerproportion(37%)rankedphysicalautomationfrst

orsecond,while24%rankedfactorysynchronizationfrstorsecond.Investmentinautomationmaybeseenasanimportantelementinalleviatingskilledlabor

shortagesandmaximizingproductivity,whilefactorysynchronizationmaymitigatetheimpactoflabor,asset,andmaterialsconstraints.

Forty-eightpercent(48%)。frespondentssaidtheyhavemoderatetosignifcantchallengesinfllingproductionandoperationsmanagementroles,and46%

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reportedthesameforplanningandschedulingroles.Themostcommonhuman

capitalconcernwasnotenterprisecultureorevenhealthandsafety.Instead,morethanathird(35%)。frespondentscitedadaptingworkerstothe"FactoryoftheFuture"asatopconcern,includingbyequippingthemwiththeskillsandtools

theyneedtoharnessthefullpotentialofsmartmanufacturingandoperations.Thechallengeofaddressingtheskillsgapcomesalongsideagapinapplicationsfor

openpositions,asfoundinthe2024DeloitteandTheManufacturingInstituteTalentstudy·

Investmentsindatareadinessandconnectivityaresettingthestageforincreasedautomation

Reportedsmartmanufacturingtechnologyadoptionisfocusedonsensors,data,

physicalautomation,andAI.Intermsofrespondents'frstandsecondprioritiesfor

thenext24months,41%saidtheywillprioritizeinvestinginfactoryautomationhardware,34%saidtheywillfocusonactivesensors,and28%reportedvisionsystems.Theinvestmentsenablethecapacitytomonitorandsensethe

manufacturingenvironment,aswellastheabilitytodriveincreasedautomation.sensing,datacapture,andautomationareprerequisitesformoreadvancedsmartmanufacturingvalue,includingthoroughanalytics,deeperoperationalinsights,andproductioneffciency.someofthisvalueisalreadycomingtofruition.

Atthefacilityornetworklevel,57%ofmanufacturersareusingcloudcomputing,thesameproportionareleveragingdataanalytics,almosthalf(46%)areusin

industrialIOT(IOT)solutions,and42%areleveraging5G.Tomanagescaled

deploymentsandgovernance,manufacturersareadoptingenterprisestandard:

Forty-fvepercent(45%)reportleveraginganarchitecturestandard;54%reportadatastandard(throughaunifeddatamodel);and48%reportatrainingand

adoptionstandard.Adoptionofanarchitecturalstrategyandstandardscanhelpsimplifydatamanagementandenhanceoperationalagility,asarticulatedinthisIndustrialDataopsanduniedNamespacecasestudy·

RespondentsarestillestablishingAlfoundationsforsmartmanufacturingandoperations

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surveyrespondentsreportedmoderateadoptionofAIforsmartmanufacturing,althoughmanyarestillearlyinexploringAICapabilities.Twenty-ninepercentareusingAI/machinelearning(AI/ML)atthefacilityornetworklevel,and24%havedeployedgenerativeAIatthesamescale.Moderateinvestmentsarealsobeing

madeinexperimentsandproofsofconcept.Twenty-threepercent(23%)。f

respondentsarepilotingAI/ML,and38%arepilotinggenerativeAI.withgenAIspecically,technologyandusecasesarestillmaturinginmanufacturing,but

acrossenterprisesandindustries,experiments,proofsofconcept,andscaled

deploymentsarepickingup,accordingtoDeloitte'sstateofGenerativeAIintheEnterpriseQ4survey.

Thatreport'sfndingstrackwithsurveydataonsmartmanufacturingpriority

investmentsforthenext24months.Lookingahead,reportedinvestmentprioritiesremaindatafocused,with40%investingindataanalytics,29%incloud

computing,29%inAI,and27%inIIOT.Byinvestinginthefoundational

technologyneededtocapture,connect,andanalyzeoperationalandenterprisedata,manufacturersareadvancingonthesmartmanufacturingmaturitycurve.

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Encounterigchaengesadrisksinsmartmafacturingtranstions

Thevalueofsmartmanufacturingmaybecomingintofocus,butsotooarethechallengesthataccompanycomplextransformations.whileorchestratingchangeandaccessingtheskilledhumancapitaltodoso,manufacturersarecontendingwithstrategicrisk,talentshortfalls,andcybersecuritypreparedness.

Thepotentialriskofbusinessdisruptionincomplextransformations

Theprimaryheadwindstosuccessfulsmartmanufacturingprogramsincludeleadershipbuy-in,technologyinvestment,resourceconstraints,change

managementandadoption,andvaluetrackingandrealization.secondary

headwindsarelabormanagement,collaborationacrossbusinessfunctions,andmacroeconomicexternalities.

Riskmanagementisalsoapriority.Almosttwo-thirds(65%)。frespondentsrankedoperationalriskasthefrstorsecondconcernrelatedtosmart

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manufacturinginitiatives.Therisksincludebusinessdisruptionandlosses

stemmingfromfailedinitiatives.Lookingmorecloselyatrisksintheoperationaltechnology(OT)environmentspecically,55%stronglyagreedthatunauthorizedaccesswasahighconcern,47%citedintellectualpropertytheft,and46%notedoperationaldisruption.Mitigatingstrategicriskisnearthetopoftheprioritylist,withsomewhatlowerreportedattentiontocomplianceandfnancialrisks.

workforceexpansionandupskiing

Manufacturersfaceasignicanttalentgap.withasmanyas3.8millionnetnew

employeesrequiredby2033tosatisfylabordemands,accordingtoa2024Deloitte

manulfactulringstuldy,smartmanufacturingmaybepartofthesolution.Themajority(85%)。fsurveyrespondentsagreedorstronglyagreedthatsmart

manufacturinginitiativeswillattractnewtalenttotheindustryasavibrantandviablecareerpath.

yet,thereremainsaneedtodaytoequiptheexistingworkforcewiththedigitalskillsforsmartmanufacturingandoperations.whilenearlyhalf(48%)。f

respondentsreportedhavingasmartmanufacturingtrainingandadoption

standardinplace,humancapitalwasatthelowestmaturitylevelofallsmart

manufacturingcategoriessurveyed.perhapsforthisreason,humancapitalisthecategoryinwhichmanufacturersexpresssomeofthehighestaspirationsfor

improvement.

cybersecurityandsmartmanufacturingtechnologypreparedness

Thechallengeofcybersecuritybecomesallthemorepressingasenterprisespursuesmartmanufacturinginitiativestocaptureandusedataforoperationalandprocessimprovements.cybertoolsareinsomecasessharedbetweenmanufacturingand

enterpriseenvironments,and44%ofrespondentssaidtheirmanufacturing

cybersecuritysolutionsareamixofbothdedicatedandsharedtools.withsomuchattentiontocybersecurity,ittracksthatsomemanufacturersarededicating,on

average,15.74%oftheirITbudget.

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Despitetheallureofcutting-edgetechnologies,suchasAI,virtualprogrammablelogiccontrollers,andevendigitaltwins,respondents'average(self-assessed)

technologymaturityreflectsthattheyaremeetingindustrystandardsfor

technology,data,andautomationbutnotexceedingthem.Inthis,thereisstill

signifcantroomforimprovement.Asitrelatestosmartmanufacturingmaturity,thesecondlargestaspirationalchange(behindhumancapital)isintechnology

readiness,whichincludestheneedtoprotecttechnologiesanddatafromcyberadversaries.

Howthesurveyedexectivesare

transformingpeope,processes,andtechooges

ontheroadtovalueandtransformation,manufacturersarepursuingwinning

approachesthatacceleratechangeacrossthetechnologyecosystem,theworkforce,andenterpriseprocesses.

coreandemergingtechnologyadoption

Manymanufacturersareintheprocessofadoptingcoretechnologieslikesensors,cloudandedgecomputing,andAI,aswellasemergingtechnologiessuchasvirtualprogrammablelogiccontrollers,robotics,andsimulations.yetrespondents

indicatedthatthestrategicapproachtodayislessaboutdeployingthelatest

innovationthanitisaboutinvestinginandadoptingcoresystemstoenablesmartmanufacturingandoperations.surveyrespondentsreportedthat,intermsof

systemsprioritizedforinvestmentinthenexttwoyears,thefrstorsecondhighest

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investmentprioritiesareadvancedproductionscheduling(35%),executionsystems(33%),andqualitymanagement(28%).

coresysteminvestmentscomealongsidesolutioninvestments,with40%ofsurveyrespondentsrankingdataanalyticsasthefrstorsecondhighestpriorityfor

investmentwithinthenext24months.solutionsofthiskindarenecessary,asmostoftheothersmartmanufacturingtechnologiesbeingadoptedgenerateorconsumedata,suchasvisionsystems,factoryautomationhardware,andactivesensors.

withanalytics-drivenvisibilityintooperationsandcyber-physicalsystems,

manufacturersenjoyafoundationuponwhichtopursuebroadertransformation.

Thevolumeofdataandconnectedsystemscreatecybersecurityrisk,aswellasvalue.Fortunately,surveyrespondentsindicatedpersistentattentiont。

cybersecuritytactics.sixty-eightpercent(68%)。fsurveyrespondentsreportedperformingacybersecurityriskormaturityassessmentoftheirsmart

manufacturingtechnologystackinthelastyear.Inaddition,asconnectedsystemscreatenewcybersecurityrisks,91%ofrespondentssurveyedforDeloitte's2024

GlobalFutureofcybersurvey,reportedoneormorecybersecuritybreachesinthelastyear:.Inthissurvey,72%to74%ofrespondentscitedinternalandexternal

penetrationtestingandvulnerabilityassessmentsasafocusinenterprise-wide

cybersecurityefforts.Interestingly,whenrespondentswereaskedwhethertheirorganizationenforcesorincorporatessecuredesignwhenimplementingnew

technologysolutions,26%saidtheydo"”henitdoesnotdelaydeployment."Theinsightisthatproductivityisaconsistentpriority,evenintherealmof

cybersecurity.

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workforceexpansionandupskilling

Themostreportedmethodforbuildingdigitalskillsetsandcapabilitiesintothe

workforcewashiringnewtalent(68%).Therewasalsoarecognitionoftheneedtoupskillemployees,includingleadership.Morethanhalfofsurveyrespondents

(53%)reportedusingin-housetrainingforexecutives,and43%leveragedtrainingcoursesdevelopedbyvendorsorthirdparties.Tosupplementcapabilitiesinthe

nearterm,40%ofmanufacturersreportedusingcontractorcontingentlabor·

whiletalentinvestmentandupskillinghappenedin-house,manufacturersalghttooutsourceaspectsoftheirsmartmanufacturingtransformationand

peration,particularlyinareaswheremanufacturersarelesslikelytoholdaCrecompetency.Between69%and72%ofrespondentsreportedmoderatet。

signihcantchallengesinhiringskilledworkersforIT,OT,datascienceand

engineering,applicationdevelopment,andcybersecurity—alltechnology-focuseddomains.Assuch,between65%and70%ofmanufacturersarecurrently

outsourcingmanyrolesacrosstechnology,data,andcybersecurity,includingthosefocusedonimplementingOT,IT,cybersecurity,analyticsandAI,andautomation.Incybersecurityspecifcally,69%ofrespondentssaidtheyrelyonthirdpartiesforcybersecuritydetectioncapabilities(forexample,asecurityoperationscenter),and73%saidtheyusethird-partysupportforcybersecurityeventresponse.

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whenconsideringwhetheroutsourcingisexpectedtochangeinthenexttwoyears,onetrendthatemergedisthatmanufacturersthatdonotcurrentlyoutsourcemanyroleswilltendtostayonthattrajectoryandllrolesinternally.conversely,

manufacturersthatdooutsourcesignicantlyreporttheywillcontinuetodoso.

Bothapproachesareviableoptionsforsatisfyingsmartmanufacturingworkforceneeds.Formanufacturersthatelecttofllrolesinternallytoretaindedicated

support,theywillneedtocompeteacrossindustriesfortalentandattract

applicantswheretherearegaps.Formanufacturersthatoutsourceroles,beneftsmayincludefractionalizedresources,task-andtime-basedemployment,and

broaderdomainexpertisepotentiallyatahigherperhourcostbutlowercost

overallcomparedtoin-houselabor.

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Howaretransformationalprocesschangesbeingdrivenacrosstheenterprise?

Adoptingandimplementingsmartmanufacturingtechnologypromptswidespreadchangetoprocessesandoperations.changecutsacrossfactories,networks,supplychains,andIT/OTenvironments,andmorethanhalf(52%)。fsurveyrespondentreporteddevelopingacentralteamorworkinggrouptaskedwithresearching

developing,anddeployingsimartmanufacturinginitiatives.otherreportedchgmanagementactivitiesincludedevelopingaprocesstocommunicatetoemployeesandcustomerstheimplicationsofsmartmanufacturing(45%),developingasmartmanufacturingcenterofexcellence(44%),anddevelopingvaluetargetsanda

measurementplanforassessingprogressagainstobjectives(42%).

Interestingly,despitethesignicantrelianceonthirdpartiesfortechnology

implementationandmanagement,only32.5%reportedengagingthirdpartiesforsupportinmanagingchangeintroducedthroughsmartmanufacturinginitiatives.Thus,mostmanufacturersaredrivingsmartmanufacturingtransformationfrom

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within,turningtooutsidesupporttosupplementactivitieswheretalentavailabilityisconstrained.

whoultimatelyownsthesmartmanufacturingchangeinitiative?Morethanhalf(51%)reportedthatsmartmanufacturinginitiativesareownedanddrivenby

operationsleaders,suchasthechiefoperatingofficeranddirectorofoperations,and38%reportedthattechnologyowners,suchaschieftechnologyoffcer,areleadingthecharge.Thefndingsalignwiththeworkforcechallengesmany

manufacturersarefacingandreinforcetheneedforITandoperationst。

collaborate.TheCOisfocusedonfllingfrontlinepositionswherecompaniesrequireskillsforasmartmanufacturingenvironmentwhiletheCTOisseekingtechnicaltalenttobuildandmaintainthetechnologyecosystemenablingsmartoperations.

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Thesmartmanufactringvisioniswithi

reachandthejourneycontsue

Backin2017,thevisionforsmartmanufacturingwa