(Rockwell Automation: Milwaukee) -- Rockwell Automation, the world’s largest company dedicated to industrial automation and digital transformation, has released findings from its 11th annual “State of Smart Manufacturing” report. The global study of more than 1,500 manufacturers across 17 countries shows a shift in industry focus: Manufacturers are no longer debating whether to adopt digital technologies, but how to execute, scale, and deliver measurable value from them.

The report reflects an inflection point for the industry as many manufacturers move beyond experimentation and toward broader deployment of digital capabilities. Fewer organizations are operating in pilot mode, while more report active use of smart manufacturing technologies to support day-to-day operations.

The study found that 90% of manufacturers now say digital transformation is essential to staying competitive, reflecting its evolution into a baseline business requirement.

“Across the industry, manufacturers are facing more complexity and pressure than at any point in the last decade,” says Blake Moret, chairman and CEO of Rockwell Automation. “What stands out in this year’s research is not just the challenges, but how leaders are responding by making digital transformation a core operating priority. The organizations that are seeing results are those that connect technology, people, and processes to turn insight into better decisions, stronger performance, and greater resilience.”

‘2026 State of Smart Manufacturing’ report key findings

Manufacturers are moving from pilots to scale

Six in 10 manufacturers (59%) report actively using smart manufacturing technologies to support operations, while only 18% remain in pilot mode, marking the decline of the pilot-heavy phase that dominated previous years.

AI is becoming the engine of industrial advantage

One-third of operations (34%) are AI-augmented today, supporting functions such as quality, cybersecurity, and process optimization. Manufacturers expect more than half of operations to be AI-supported by 2030, reinforcing AI’s role as a core operational capability.

Operational intelligence is now a competitive divider

While organizations continue to collect growing volumes of data, only 43% are being used effectively, highlighting execution—not data availability—as a constraint on performance.

Cybersecurity is an operational reality

Nearly half of manufacturers (46%) experienced at least one cyber incident during the past year, reflecting rising exposure as operations become more connected and autonomous. Secure, integrated IT/OT architectures are now foundational to scaling AI and advanced automation.

The report also finds that manufacturers are focusing transformation investments on measurable outcomes—improving quality, reducing cost, lowering operational risk, and increasing overall equipment effectiveness. One-third of operating budgets remain dedicated to industrial technology, signaling sustained, execution-focused investment rather than short-term experimentation.

The “2026 State of Smart Manufacturing Report” draws on more than a decade of global research to highlight the capabilities shaping modern industrial operations, including intelligence, resilience, adaptability, and workforce transformation.

The complete report is available here.

Methodology

This report analyzes feedback from 1,560 respondents from 17 of the top manufacturing countries representing roles from management through C-suite. Conducted by Sapio Research in association with Rockwell Automation, the survey sampled from a range of industries, including consumer packaged goods, food and beverage, automotive, semiconductor, energy, life sciences, and others. With a balanced distribution of company sizes with revenues spanning $100 million to more than $30 billion, the report offers a wide breadth of manufacturing business perspectives.