Hyperautomated factories

These findings are taken from the Accenture study"Rethinking the course to manufacturing's future", for which Accenture surveyed 552 factory managers from the mechanical engineering, automotive and aviation sectors worldwide in December 2024.

The study describes the importance of AI, automation and digitalization for the future of manufacturing. Around half of those surveyed expect hyperautomation technologies and applications to shape the image of factories in 2040. The figure is significantly lower in Germany and Europe. The surveyed core elements of the factory of the future include

• Autonomous operating processes (Industry 5.0): Approval worldwide is 53%, in Germany only 40% and in Europe as low as 38%.
• Self-learning machines with generative AI are approved by 52% worldwide, but only 42% in Germany and 39% in Europe.
• Fully automated warehouses are considered crucial by 51% of respondents worldwide, compared to 38% in Germany and 35% in Europe.
• Intelligent, networked production cells are seen as relevant by 49% globally, but only by 27% in Germany and 31% in Europe.
• Autonomous mobile robots (AMR) are prioritized by 49% globally, 42% in Germany and 32% in Europe.
• Digitally networked and interacting teams receive 48% approval worldwide, 31% in Germany and 30% in Europe.
• Digital twins of operational processes are considered important by 47% worldwide, but only by 29% in Germany and Europe.
• Automated guided vehicles (AGVs) are considered relevant by 45% of respondents worldwide, compared to 31% in Germany and 25% in Europe.

In China and Japan, the approval ratings are significantly higher at 51% to 83%.

Dark Factories and Co.

The more advanced the concept, the clearer the regional differences:

• 74% of factory managers in Japan assume that their company will primarily build 'dark factories' in 2040 (China: 53%, USA: 29%, Europe: 20%). In Germany, the figure is only 24%.
• At the same time, 72% of respondents in Japan, 65% in China and 35% in the USA believe that humanoid robots will be standard in their companies' assembly processes. The figure is significantly lower in Germany (23%) and Europe (21%).

Hyperautomation requires a reorganization of work

Hyper-automated factories are changing the way employees work, their roles and the skills they need. As a result, 70% of factory managers consider workforce transformation to be the most important enabler of the manufacturing of the future, followed by automation (63%), AI (62%) and digitalization (61%).

In Germany, 53% prioritize the transformation of the workforce (Europe: 58%), 53% automation (Europe: 51%), 54% AI (Europe: 51%) and 48% digitalization (Europe: 49%).

The preservation and transfer of production knowledge is particularly crucial for the transformation of work and the workforce (globally: 74%, Germany: 54%, Europe: 64%). They also see the integration of data analysis (global: 73%, Germany: 58%, Europe: 64%) and data-supported decision-making (global: 72%, Germany: 63%, Europe: 64%) as essential.

For almost half of respondents worldwide (49%) and in Germany (48%), extensive investment in training programs is the biggest obstacle to workforce transformation. On average, European companies see less need for action in this area (43%). The situation is very different in China, where 62% see the necessary investment as a challenge.

Another barrier is the workforce's fear of losing their jobs, according to 46% of all respondents. This is slightly less pronounced in Germany and Europe (40%). The fear of losing one's job is most widespread in India (70%). In addition, the resistance of the workforce to new, expanded work roles is slowing down the transformation, according to 38% of respondents. The figure is even higher in Germany and Europe (46%), with Italy leading the way at 66%. New roles include Human-Robot Collaboration Manager or Autonomous Logistics Coordinator.

Worldwide, 51% of factory managers complain about a shortage of skilled workers with AI knowledge and qualifications. This problem is perceived particularly strongly in India and Japan (67%), but to a much lesser extent in China (40%). In Germany, 46% of factory managers see a shortage of AI specialists as a problem, compared to 49% in Europe.

Overdue digitization measures

Factory managers around the world are setting clear priorities for digitalization measures that are actually already overdue. Cybersecurity is in first place (77%), followed by the introduction of manufacturing execution systems (70%) and cloud platforms (67%). The figures for German and European respondents are below the global average for all measures. The study does not provide any information as to why they see less need for action in these areas.

According to the study, however, it is worrying that technologies such as the Industrial Internet of Things (IIoT) and digital twins of machines and products are among the top priorities in hardly any country. After all, these technologies form the digital basis of modern factories.

To the study

In December 2024, Accenture surveyed 552 experienced factory managers in Asia (China, India, Japan), Europe (Austria, Denmark, Finland, France, Germany, Italy and Switzerland) and the USA. The respondents represent automotive manufacturers and suppliers, mechanical and plant engineering companies, electrical equipment manufacturers and aircraft manufacturers and suppliers.