Rockwell Automation’s Smart Factory Solutions Bridge Manufacturing Skills Gap

Manufacturing employment remains near historic lows, yet the sector has sustained steady job growth over the past decade. Automation has driven this resilience, but attracting a younger workforce remains a critical challenge.

In 2018, the U.S. Bureau of Labor Statistics reported a median age of 44 for manufacturing employees—a trend mirrored across industrial sectors. While many national workforces age, the manufacturing segment faces a pronounced gap. Deloitte estimates that between 2018 and 2028, this skills shortfall could erode $2.5 trillion of economic output. The firm noted the sector’s labor market has become one of the tightest in history, with job openings sometimes outpacing the pool of qualified candidates.

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Beyond the skills gap, manufacturers confront persistent uncertainty—from globalization and rapid product diversification to compressed life cycles and recent trade tensions.

This volatility drives a surge in digital technology adoption across manufacturing and beyond. “In uncertain times, operational efficiency becomes paramount to weather downturns and maintain competitiveness,” says Reggie Walker, PwC’s Chief Commercial Officer.

Industrial leaders now focus on two core digital pillars: industrial IoT (IIoT) platforms and manufacturing execution systems (MES). Gartner notes the convergence of these solutions; its latest Magic Quadrant predicts that half of MES products will integrate closely with IIoT platforms and manufacturing operations management applications.

Rockwell Automation ranks among Gartner’s top MES vendors, alongside SAP, Siemens, Oracle, AVEVA, and Dassault Systèmes. Its distinctive edge comes from a strategic partnership with PTC—a leading IIoT platform provider. In 2023, Rockwell invested $1 billion in PTC, birthing the FactoryTalk InnovationSuite that merges capabilities from both firms.

Keith Higgins, Rockwell Automation’s VP of Digital Transformation, identifies key disruptors in the industry. Chief among them is edge computing—shifting data processing closer to the source—and the growing need for real‑time insights.

Beyond edge computing, contextualizing operational technology data is a priority. “Rockwell’s century‑old install base now harvests OT data via digital twins and IIoT,” Higgins explains. He notes that companies are moving beyond buzzwords, realizing tangible productivity and time‑to‑market benefits by integrating analytics, MES, and augmented reality into their operations.

Earlier this year, Rockwell Automation merged its deep control and automation expertise with PTC’s strengths in IIoT and AR to deliver the InnovationSuite—an integrated platform that unifies MES, analytics, and immersive technologies.

Within the last year, Rockwell and PTC onboarded over 100 joint customers to the InnovationSuite. The solution is targeting high‑digital‑maturity sectors—consumer packaged goods, healthcare, oil & gas, and pharmaceuticals—where diverse end‑user needs converge.

Higgins highlights augmented reality as a powerful tool to counter the widespread labor shortage. PTC’s Vuforia Expert Capture lets seasoned technicians capture procedures with visuals, audio, and annotations—translating decades of expertise into a consumable format. Paired with AR headsets like Microsoft HoloLens and RealWear HMT‑1, the system empowers newcomers to tap into the organization’s “tribal knowledge.”

Although the sector still faces a retirement wave, modernization is revitalizing manufacturing, making it more attractive. “Digital transformation—especially AI, robotics, and AR—will draw new talent into the industry,” Higgins asserts.