Discover how small, scalable steps in data utilisation can revolutionise manufacturing, enhancing efficiency and driving Industry 4.0 and 5.0 advancements.
Data-driven decision-making isn’t just an advantage anymore; it’s becoming the dividing line between those who lead and those who fall behind. Big data analytics is no longer optional; it’s essential for improving efficiency, cutting waste, and adapting quickly to market changes. With Industry 4.0 already reshaping operations and Industry 5.0 emerging, companies that don’t rethink their approach to data risk being left behind.
Digital technology is transforming the way manufacturers work. By using sensors in machinery, companies can move from reacting to problems to preventing them, identifying inefficiencies before they lead to costly breakdowns. But it’s not just about machinery; integrating data across supply chains helps manufacturers anticipate demand, avoid overproduction, and improve logistics.
The numbers tell the story. Grandview Research valued the UK Industry 4.0 market at $9.48 billion in 2023, with projections rising to $30.57 billion by 2030, growing at a rate of 18.2% per year. This isn’t a passing trend, it’s the future of manufacturing.
Data is no longer just a by-product of production; it’s the key to smarter, more efficient manufacturing. Real-time analytics and IoT sensors help predict maintenance needs, optimise processes, and improve resource use. AI-driven insights further refine operations, ensuring quality, reducing waste, and keeping costs down.
Yet, despite the clear benefits, many UK manufacturers have been slow to adapt. Make UK reports that the sector remains the eighth-largest manufacturing economy, employing 2.6 million people, but progress towards Industry 4.0 has been patchy.
A five-year study by Protolabs and The Institution of Mechanical Engineers highlights shifting attitudes. In 2019, the biggest barriers to digital adoption were a lack of knowledge and awareness. By 2023, confidence had doubled, with 65% of respondents saying they were ready for digital transformation. However, cost is now the primary hurdle, 70% of manufacturers cite financial constraints as the main reason they have not fully embraced automation.
A common misconception is that becoming data-driven requires a complete overhaul of equipment, making the financial challenge seem even greater. In reality, retrofitting existing equipment with sensors or finding ways to extract data from OEM equipment is a cost-effective way to start gathering insights.
At MARCH, we have seen first-hand how data-driven strategies can transform manufacturing operations. A great example comes from one of our food and beverage clients; a crisp manufacturer aiming to improve efficiency and reduce waste. Historically, packets moving through weighing machines would either pass or be rejected. Without centralised data, it was impossible to see patterns or pinpoint problem areas.
MARCH delivered a project that collected and analysed data from individual machines before assessing it collectively. This revealed inefficiencies, such as packets being consistently overfilled or too many being rejected due to minor inaccuracies. By isolating underperforming machines, they are now able to optimise the production line, reducing waste and improving efficiency. Importantly, they didn’t need to replace existing equipment. MARCH helped them access and use the data they already had but weren’t using.
This approach has now been replicated across multiple sites, allowing the company to benchmark performance and drive improvements on a global scale.
When thinking about data-driven manufacturing, it’s easy to focus on analytics, but that’s just the tip of the iceberg. Beneath the surface lies the essential infrastructure: IoT systems, integration, data collection, PLC control, networking, and the decision of whether to process data at the edge or in the cloud. Without this foundation, meaningful analysis isn’t possible.
For every data expert, multiple engineers are needed to build and maintain these systems, and they need to be subject matter experts. This is where MARCH has a clear advantage. With expertise in digital, process, and infrastructure and deep sector knowledge, we understand the full factory environment. Our approach ensures that data projects are not just theoretical but are rooted in real operational needs, enabling manufacturers to unlock real value.
Despite growing confidence in digital manufacturing, the pace of automation remains slow. The Protolabs study found that in 2023, nearly half (49.5%) of respondents had automated between 25% and 50% of their operations, a significant step forward, but still far from full adoption. Many companies hesitate due to investment concerns, but the risk of inaction is even greater.
Taking small steps, starting with pilot projects and scaling up gradually, can ease the transition and reduce financial challenges. The key is to focus on high-impact areas first, ensuring that investment delivers tangible benefits before expanding digital initiatives further.
The message is clear: the future of UK manufacturing depends on how well businesses use data. Companies that invest in analytics, upskill their workforce, and create a strong digital strategy will thrive. Those that hesitate risk being left behind in an industry that is evolving faster than ever.
For more information on how MARCH can help you leverage data to transform your manufacturing operations, email me directly at [email protected] or visit march-engineering.com / Contact – March, Engineering Progress.
Michael Thomas, Managing Director, Digital, MARCH.
Michael is Managing Director for Digital at MARCH a leading provider of critical engineering services. With a background in Operational Technology and business, Michael focuses on leading digital growth and collaboration and cutting-edge digital technologies.
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