How Sensors are Transforming Manufacturing Today and Tomorrow

Manufacturing is becoming increasingly data‑driven, and sensors are at the heart of this transformation. By capturing real‑time metrics, they enable plants to boost productivity, reduce downtime, and streamline maintenance.

Key Findings from a Forrester Research Study

Forrester’s latest study—commissioned by ATS—reveals that 85% of industrial firms expect data‑driven decision making to dominate maintenance within the next five years. In response, half of these companies are expanding their maintenance budgets to adopt new technology and upgrade existing programs.

Retrofit Over Replace

While smart, sensor‑enabled equipment is available, most facilities opt for retrofitting existing machinery or adding standalone sensors. This approach delivers the benefits of IIoT without the cost of full equipment replacement.

Remote Sensors as Catalysts

Remote IIoT sensors can monitor legacy machines and transmit usage data, driving adoption of predictive maintenance without a major capital outlay.

Challenges to Adoption

• 35% of facilities report resistance from staff who prefer instinct over data.
• 39% struggle to find employees comfortable handling the volume of sensor data.
• 40% face integration difficulties, underscoring a skills gap that hampers sensor effectiveness.

The Sensor Landscape

Manufacturers employ a wide array of sensors—vibration, pressure, temperature, and more. While 86% use five or more types and half use seven or more, selecting the right mix can be confusing without clear guidance.

Benefits and Pitfalls

Without proper training and a culture that embraces data, sensor investments can become sunk costs. A holistic strategy—including skilled personnel, targeted training, and process realignment—is essential to unlock full value.

Why Sensors Matter Now

Industries recognize that sensors are the future of maintenance. When correctly implemented and staffed, they reduce downtime, improve equipment utilization, and elevate overall productivity.

ATS leads in outsourced maintenance and predictive technologies. We provide the expertise and trained staff needed to integrate sensors seamlessly into your operations. Contact us today to maximize your investment.

Download the full commissioned study conducted by Forrester Consulting on behalf of ATS here.