Manufacturing organizations are continually seeking ways to gain an edge. They may need to compete with foreign manufacturers by reducing waste and increasing efficiency. They may have to scale production quickly to meet demand. From a staffing standpoint, they can attract and retain skilled workers by providing modern tools that enhance productivity. Meanwhile, they must comply with regulators that require digital traceability, cybersecurity, and sustainability.
Image Source: Monchisa/stock.adobe.com.
The era of digital manufacturing is here. Companies that move early to integrate these tools will lead the reshoring movement, while laggards risk being left behind. According to a 2025 survey of manufacturing professionals by Cadalyst and IMAGINiT Technologies, technology plays a key role in addressing challenges faced by manufacturers, though technology also presents its own challenges. In this article, we gather and present the issues from the survey responses, along with our conclusions and recommendations. Because of these realities, IMAGINiT is meeting manufacturers where they are today to better understand how the technology sector can help.
What are the primary challenges your organization currently faces?
Identifying and Addressing Challenges
When asked to identify the primary challenges faced by their organization, over 40% of survey respondents cited reducing operational costs and retaining staff as key concerns. Managing design data was another top challenge, at approximately 36%. A variety of other challenges related to technology and business processes were also identified. The results indicate that a combination of both process- and people-related items require attention.
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To overcome industry challenges, firms are increasingly turning to technology. Over 40% of respondents cited cost reduction as a key expected benefit of digital investments, while more than 50% highlighted minimizing errors and rework as the top priority. Manufacturing firms clearly see digital tools as essential for improving efficiency and addressing operational hurdles.
What are the top two outcomes driving your digital investments?
Digital technology can help address many of the challenges facing manufacturing firms, but before looking at adopting specific technology tools, firms would be wise to step back and review their overall digital strategy. Does the firm have a clear, comprehensive plan on implementing technology, or is it more reactive, responding to trends as necessary, possibly long after competitors have already done so? Apparently, most firms put themselves in the latter category. When asked to describe their organization’s digital strategy, over 56% said their digital strategy was reactive.
Respondents expect that making further digital investments will reduce costs. Image source: tippapatt/stock.adobe.com.
How would you describe your organization’s digital strategy?
The reactive approach to digital strategy may be preventing firms from capitalizing on technology benefits. When considering operational improvements in manufacturing, “the focus is often on reducing costs to make something out on the shop floor,” said Jason Barnett, Vice President of Manufacturing & Product Lifecycle Management at IMAGINiT Technologies. A more strategic approach is to view operations as “an ecosystem where you’re trying to reduce the friction that might be limiting operations,” he said. Barnett said an effective digital strategy can help address many of the challenges firms are facing, such as efficiency improvements and staff retention. By properly planning for and implementing technology, firms can improve efficiency and reduce costs in a variety of ways, such as minimizing rework, improving communications, and increasing efficiency of meetings and phone calls. To improve staff retention, digital strategies should focus on keeping technology up to date and providing thorough training. “If you don’t give employees modern tools and you don’t train them how to use things, you’re setting yourself up for turnover,” said Barnett. An effective training program is tailored to the organization’s needs, with some combination of in-person, online, and on-demand formats.
Automatic Systems, Inc., a provider of turnkey solutions for conveyor systems and automation in airport baggage and automotive manufacturing environments, has found value in IMAGINiT’s ProductivityNow eLearning and support platform. “It is a single location for individuals to find information they’re looking for, and at the time they need it,” said Mike Wohletz, ASI CAD Manager.
Data Management is Key
Another key component of a digital strategy is data management. Over 50% of respondents said design changes represented their top data management challenge, followed by project tracking, integration, version control, and security.
Specific challenges aside, data management may represent the key to success for many organizations. “It’s putting data at the center, making the data accessible, where people can find the right information when they need it,” said Barnett. Particularly with engineering and manufacturing data, exposing data to the appropriate parts of the business at the right time is key to improving efficiency and other key performance indicators.
What are your top data management challenges?
“If firms don’t have data management under control, they’re not going to get to automation or artificial intelligence (AI) or other advanced technologies,” added Barnett. “They’ve got to get the house in order first.”
Tools such as Autodesk Vault and Autodesk Fusion Manage, among others on the market, can help with product data management (PDM) and product lifecycle management (PLM) in manufacturing environments. With tools such as these, teams can better manage design changes, project tracking, and other product development processes.
How do you currently manage design collaboration?
Collaboration
Along with data management, collaboration is an area where manufacturing firms may find opportunities for improvement. When asked to identify how their organization manages design collaboration, over 60% of respondents said they still use antiquated methods such as email and shared network drives for data collaboration. Less than 30% used more modern technologies such as design collaboration platforms, PDM/PLM systems, and cloud storage.
The slow adoption of design collaboration platforms is also limiting firms’ ability to share information efficiently, according to Barnett. Collaboration platforms have advanced significantly in recent years and have become much easier to use. With tools such as Autodesk Fusion, information can be tracked and tied to specific projects or products, with the system automatically notifying and delivering information to people as needed, rather than via manual processes. In particular, Fusion Manage provides a cloud-based PLM solution geared for collaboration in manufacturing environments.
Collaboration is key in manufacturing. Use of a PLM solution will help product designers and manufacturers be more successful. Image source: Jirakrit/stock.adobe.com.
What percentage of your design tasks are automated?
Automation: Untapped Potential
Automation represents another area where firms can gain efficiency. By automating tedious, multi-step processes, workers can focus on more critical, judgment-oriented tasks. Despite these opportunities, many manufacturing organizations are automating relatively few design tasks, according to the survey.
The majority of respondents said that less than 10% of their design tasks are automated. “It’s taking that mundane, repeatable stuff and letting the machine do it instead of a human,” said Barnett. The survey responses indicates that as an industry, “manufacturing is lagging in automation.”
WireCrafters has seen a 40% decrease in the time it takes on a design. Image source: WireCrafters.
WireCrafters, a producer of wire partition products, realized major efficiency gains through automation. The firm engaged IMAGINiT to develop the Engineering Takeoff Automated Processes (ETAP) system, which includes web-based parts libraries, a web-based sales configurator tool, and numerous other features. With the new automated process, salespeople create computer-generated quotes and relay information to the engineering department, which uses the information in the ETAP program to populate 3D models and create customer approval drawings, along with detailed cut sheets for takeoff.
“We are experiencing a 40% decrease in the time a design spends in our engineering departments,” said J.R. Marsteller, WireCrafters Engineering Manager.
“Our company and our customers are reaping the benefits; our teams can take on more work with faster turnaround times on approval drawings and get custom jobs into the shop much quicker.”
What prevents further automation (select top 2)?
Survey respondents cited a variety of reasons for not automating. Over 60% said custom design needs prevented them from automating. IMAGINiT’s Barnett said this may warrant a closer look at many organizations. While most manufacturing firms have some custom operations, not everything is custom. “Most organizations make the same things over and over again,” he said. “There’s no reason to not automate many more things.”
Cost may also be less of a concern than perceived by those unfamiliar with automation. Often customization can be accomplished with tools already in use at most firms, such as AutoCAD and Inventor, according to Barnett. Costs for development time can often be recouped quickly and result in significant cost savings in the long run.
Some users are evaluating generative AI and advanced simulation, others interested in digital twins and more. Image source: Supatman/stock.adobe.com.
Which technologies are you evaluating for the next 12–18 mo?
Implementing New Technologies
Regarding new technologies being evaluated, generative AI and advanced simulation led the way, with approximately 29% of respondents evaluating one or both of those technologies over the next 12 to 18 months. Digital twins and augmented reality/virtual reality (AR/VR) followed at 16% and 13%, respectively. A handful of other technologies, such as 3D printing, PDM, and enterprise resource planning (ERP), were also identified. In a separate question, costs, training, integration, and uncertain return on investment (ROI) were cited as concerns in adopting new technologies.
How do you expect your design processes to change in the next 3–5 years?
Looking out three to five years, a majority of respondents anticipate more automation and collaboration to be introduced in their operations. AI and machine learning was also identified, along with a greater focus on sustainability.
Considering the challenges facing manufacturing organizations, technology can offer many solutions to directly address these challenges. Adopting new technology first requires a well-planned digital strategy and solid data management plan. An experienced partner such as IMAGINiT Technologies can help you develop such strategies and guide you in implementing new technology, as well as more effectively using technology already in place.
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This survey and whitepaper were produced in cooperation between IMAGINiT Technologies and the editors of Cadalyst.
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