Quality Digest attended the 2025 Hexagon Live event in Las Vegas in June—and with that came the opportunity to speak with the great minds, creators, innovators, and sales teams of Hexagon. Darren Metherell, head of sales at Hexagon, followed up with the QD team after this event to speak more about connected manufacturing, and how cloud-based platforms like Nexus are improving communication, efficiency, productivity, and profitability by integrating disparate systems and seamlessly transferring knowledge.

Quality Digest: First off, let’s define connected manufacturing. What is it, and what makes it the smarter, more efficient way to get things done?

Darren Metherell: Connected manufacturing is the integration of digital technologies, intelligent systems, and real-time data across every stage of the production process, from design to delivery. It replaces disconnected, manual workflows with a seamless digital thread that enhances visibility, coordination, and decision-making across the entire value chain.

Six core features define connected manufacturing.

1. IoT integration: Smart sensors and devices collect and transmit operational data, enabling better monitoring and control of equipment, materials, and environments.

2. Real-time data: Data flow continuously between systems and teams, allowing for timely decisions and immediate issue resolution.

3. Automation and robotics: Repetitive or complex tasks are handled with precision by automated systems, improving speed, safety, and consistency.

4. Cloud computing: Cloud-based platforms centralize data and make it accessible across locations, reducing infrastructure complexity and enabling remote collaboration.

5. AI and machine learning: Algorithms uncover patterns, predict issues, and recommend optimizations, helping manufacturers proactively improve outcomes.

6. Digital twins: Virtual models of equipment or processes simulate real-world performance, allowing for predictive maintenance, scenario testing, and continuous improvement.

Together, these technologies create the agile, data-driven, and efficient operations that we call “smarter manufacturing.”

QD: We all know that access to accurate, up-to-date data is vital in manufacturing. How does having that information readily available for workers on the shop floor improve the quality of products and services in the industry?

Metherell: Having accurate, up-to-date information enables the shop floor to make quicker decisions and can also lead to avoiding unwanted outcomes of a manufacturing process. This reduces or eliminates scrap and can also improve the product quality by using machine learning along with digital twins to ensure the highest efficiency possible, both in cycle time and in material waste.

It really comes down to faster reaction time and avoiding an unwanted outcome altogether.

QD: How does Nexus, in particular, work toward the goal of connected manufacturing?

Metherell: If you look at the six key features of connected manufacturing, Nexus and the greater Manufacturing Intelligence Division are directly involved in each of them.

Nexus Connected Worker enables disparate systems to communicate seamlessly with one another, removing the friction that often exists between departments and software platforms. It creates dynamic digital workflows that not only provide shop floor workers with the information they need but also capture their input and translate it into meaningful action. Rather than relying on siloed data or outdated methods, Nexus gives operators real-time visibility and clear direction, making it easier to consistently do the right thing at the right time. This level of integration improves traceability, accountability, and overall process coordination—key pillars of any connected manufacturing strategy.

QD: How does Nexus break down silos and decrease downtime/improve productivity?

Metherell: Nexus helps manufacturers overcome siloed operations by making it easier to communicate, collaborate, and act across teams. One way it does this is by enabling automated, targeted notifications, ensuring that the right people are informed as soon as something important happens. That immediacy helps reduce response times and prevent minor disruptions from snowballing into major downtime.

Nexus also facilitates real-time collaboration within workflows, allowing team members to contribute insights or approvals right when and where they’re needed without relying on disconnected tools or delayed communication. Because all data are updated continuously, dashboards reflect the current state of operations, giving supervisors the visibility they need to identify issues and take action quickly. This makes it possible to adopt a “manage by exception” approach, where managers focus their attention only where it’s needed, driving both responsiveness and productivity.

QD: What effect does this have on profits?

Metherell: The profit impact of connected manufacturing is often both immediate and long-term. By cutting down on scrap, reducing downtime, and accelerating throughput, manufacturers can significantly lower operating costs and increase output without adding head count or equipment. Improvements in product quality also lead to fewer rework cycles and warranty claims, which can otherwise be expensive and reputation-damaging. The savings can be substantial: Depending on the size of the operation, organizations may recoup thousands, tens of thousands, or even hundreds of thousands of dollars per month. 

Beyond the financial metrics, there’s a strategic benefit as well. Companies that embrace connected workflows position themselves for continuous improvement, better decision-making, and greater resilience in a competitive and often unpredictable market.