Loading
Magazine |

8 Key Industrial Automation Trends in 2025

Rapidly accelerating digitization, fueled by technologies like AI, is enabling manufacturers to boost efficiency and address the skilled labor shortage.

Share This:

LinkedInLinkedIn
XX
FacebookFacebook
PrintPrint
EmailEmail
Female worker looking toward viewer through coding and other symbols representing artificial intelligence and smart manufacturing.

By Theresa Houck, Executive Editor

EDITOR’S NOTE: Listen to our Automation Chat podcast, “8 Key Industrial Automation Trends in 2025

,” with Executive Editor Theresa Houck as she reviews the important trends and technologies discussed in this article. Listen on your favorite podcast app or on the web
.

Manufacturing continues to undergo stunning transformation. The pace of automation is accelerating, with more organizations creating fully automated value chains. Digital transformation can be complex and a little overwhelming, so it’s important to know what trends are affecting you — and which ones are more hype than reality.

Our analysis of the 8 key industrial automation trends highlights the critical interplay between technological advancement and workforce development for manufacturers and producers seeking to achieve business success and gain a competitive edge. And all these trends revolve around digitization — the Industrial Internet of Things (IIoT) — and it’s all about data.

Let’s examine the trends affecting you now and their ongoing impact on your operations.

1. Industrial Internet of Things (IIoT)

The IIoT and connecting operations has moved beyond trend to a standard way of doing business. It’s a broad term that covers the digitization of operations. Also called Industry 4.0 or smart manufacturing, the IIoT means connecting machines and devices for real-time data monitoring and creating smart, optimized operations.

The IIoT encompasses technologies such as edge computing, cloud computing, digital twins, artificial intelligence (AI), vision systems, smart human-machine interfaces

(HMIs), augmented reality (AR), connected worker technology and other ways to help create smart, connected industrial operations. Let’s take a closer look at some of these.

2. Edge Computing and Cloud Computing, Separately or Together

Edge computing processes data closer to its source for real-time analysis, and it’s ideal for industrial firms that don’t have on-site IT expertise. It provides distributed intelligence at or near physical processes to sense, control, run local programs and communicate with industrial controllers, plant operations, enterprise systems and cloud applications.

The major advantage of using edge devices close to physical production is achieving fast response times with low latency and capturing real-time data. Incorporating higher-level functions into these field devices and industrial controllers can reduce the need for middleware software.

Meanwhile, cloud computing can be useful for any company, and particularly for small and medium-sized firms that can’t or don’t want to make a large investment in on-site systems. Cloud-based solutions reduce overhead and simplify remote data access.

In fact, some manufacturers integrate both edge and cloud computing. For example, edge computing performs real-time monitoring and machinery control, while cloud computing powers data analytics, storage and access. Both technologies offer strong cybersecurity postures.

Workers operate smart machines to manufacture LED products for semiconductors in China.
Partners Provide IIoT Technology

Rockwell Automation Technology Partners deliver proven and integrated solutions that enhance quality of your design and implementation projects. They’re best-in-class suppliers, and they’re backed by application knowledge and unparalleled support.

Many of partners supply advanced technologies supporting IIoT trends. Visit the Partner Locator using the button below to learn how these partners can help you.

  • Artificial Intelligence: NVIDIA
  • Augmented Reality & Design Software: EPLAN GmbH & Co. KG; Maplesoft
  • Edge Computing, Data Platform & Industrial Algorithms: Festo, Stratus Technologies
  • Energy Monitoring: Grace Technologies, Spectrum Controls
  • Human-Machine Interface (HMI) Hardware & Software: Pepperl+Fuchs, SeQent, Spectrum Controls, Zebra Technologies
  • Robotics: autonox Robotics, Comau, DENSO Robotics, Doosan Robotics, FANUC, Weiss North America
  • Sensors & Switches: Advanced Micro Controls Inc. (AMCI), Ametek, NK Technologies, SMC Corp.
  • Sustainability Solutions: Dialight, Optimum Energy LLC, Southwire Co.
  • Virtual Reality: EPLAN GmbH & Co. KG; Maplesoft
  • Vision Systems: Hermary, IMPERX, Motorola Solutions, Teledyne DALSA
  • Wiring & Connection Devices: Hubbell, Leviton Manufacturing Co., Panduit, Service Wire Co., Southwire, icotek Corp.
  • Wireless 5G Connectivity: Ericsson, Nokia
Learn More

3. Artificial Intelligence (AI) and Machine Learning (ML)

AI and ML are some of the most exciting and talked-about technologies affecting automation and is a growing part of the IIoT space. AI supports a new way of working; the software acts as more of a collaborator than a tool, allowing machines to learn, adapt and make decisions on their own. This can increase efficiency as well as help mitigate the skilled worker shortage.

The potential for its benefits is limitless and still to be explored. Industrial firms already can use it to:

  • Optimize the design process.
  • Identify asset patterns and anomalies to optimize production.
  • Predict supply chain issues.
  • Enable predictive maintenance to become increasingly sophisticated with advanced functionality.
  • Perform quality control and inspection.
  • Slash downtime.
  • Improve time to market.

In addition, industrial robots and drones can use AI to improve their precision and help with tasks such as inspection, maintenance and material handling. This reduces the need for human intervention and lowers the risk of accidents, improves maintenance efficiency and increases equipment life.

AI can also help employees research, write, collaborate and develop ideas, helping them to better understand their work and to work faster and with confidence.

One of the challenges manufacturers and producers face is figuring out if and how they can use AI and ML. Automation suppliers offer numerous options and can help evaluate whether AI is a feasible option (see sidebar).

4. Wireless Private 5G Connectivity

Wireless private 5G connectivity

continues to revolutionize manufacturing. Digitalization requires getting reliable, fast and actionable information for real-time control into the hands of users, including process operators, maintenance technicians, environmental health and safety professionals, and supply chain workers. And that makes wireless private 5G a game changer for industrial firms.

Wireless private 5G is considered by many to be superior to industrial Wi-Fi because of higher speeds, easy deployment and lower initial and life-cycle costs. Older controllers without Ethernet connections can be interfaced to the plant system network using Ethernet gateways.

Other advantages compared to the private long-term evolution (LTE) wireless standard include:

  • Faster data transmission.
  • Lower latency.
  • Ability to connect to more devices in a defined area.
  • Ability to maintain connections among more sensors than previous wireless protocols. In fact, private 5G supports seamless communication across thousands of devices and systems simultaneously. Manufacturers can fully exploit IIoT sensors, autonomous robotics and advanced analytics without being constrained by network bottlenecks or dead zones.
  • Exceptional security, offering advanced encryption protocols, network slicing and user authentication features for maximum protection. For IT managers, this means better data governance and simplified compliance with industry standards.
  • Optimized production processes, allowing manufacturers to cut downtime, streamline workflows and increase throughput.
Smart industry control concept.Engineer Hands holding tablet on blurred robot arm automation machine as background
IIoT-Enabling Technology from Rockwell Automation

Rockwell Automation leads the way in helping manufacturers and producers by providing market-leading hardware, software and services to help companies on their digital transformation and industrial automation journeys. Below are just a few of the advanced technologies the company provides to help industrial firms create smart manufacturing plants. Visit www.rockwellautomation.com

to learn more.

  • Digital Solutions from Kalypso: A Rockwell Automation Business.
    Providing consulting, digital, technology, business process management and managed services across the innovation value chain.
  • FactoryTalk© Analytics™ LogixAI
    ©: Empower OT personnel with out-of-the-box AI for production optimization.
  • FactoryTalk Design Studio
    ™ with Microsoft’s Azure OpenAI Service: A cloud-based, software-defined industrial automation design environment FactoryTalk Design CoPilot; engineers can use natural language prompts with generative AI tools for tasks such as product guidance, code generation and troubleshooting.
  • OTTO Motors by Rockwell Automation:
    next-generation autonomous robots enhanced with NVIDIA AI technologies.
  • Emulate 3D
    digital twin software
    .
  • Vuforia Augmented Reality
    Technology from Rockwell Automation.
  • Workforce Development Training Services.
  • Renewable Energy Solutions:
    Enabling efficient, sustainable renewable energy production.
  • ThingWorx IIoT Solutions:
    Connects disparate devices, applications and data sources across the enterprise, providing a single source to collect, aggregate and enable secure access to industrial operations data.
Learn More

5. Digital Twins

A digital twin

is a virtual representation or digital model of a real-world physical object, system or process. Users can simulate, monitor and analyze the digital twin’s behavior to optimize performance, make informed decisions, and predict potential issues before they occur in the real world. It’s a chance to test it before producing the final physical object.

A critical part of digital twin creation

is the need to have a complete data set, including the capture of real-time information. To collect this information, strategies can include using existing connected sensors, adding new sensors to existing PLCs and controllers, and installing edge devices and smart sensors.

Use of digital twins will continue to increase as industrial firms look to slash development time and costs, lower time to market and achieve real-time integrated manufacturing.

Future trends of digital twins will include managing intricate simulations, ranging from supply chains to smart cities, to enable large-scale predictive maintenance and real-time monitoring. Another emerging trend is using digital twins in sustainability initiatives, such as maximizing energy efficiency and reducing environmental effects.

6. Robots and Cobots

The IIoT and AI are accelerating robotic evolution. Enhanced flexibility and adaptability are making robots sophisticated collaborators, vital for increasing efficiency, productivity and sustainability while helping to mitigate the skilled labor shortage. And with cutting-edge sensors and 3D vision systems, robots can perform more complex tasks and tasks that demand precision.

Other advantages robots will continue to provide include:

  • Enhancing precision.
  • Increased safety.
  • Higher efficiency across tasks such as welding, manufacturing, assembly and quality control.
  • Advanced sensor technology for improved human-robot interaction.
  • Edge computing to analyze real-time data.
  • Availability of autonomous mobile robots (AMRs) for material handling.
  • The use of wireless private 5G for fast and reliable data transmission from robot sensors throughout the plant floor for real-time data analysis.
  • Virtual simulation so robot programmers and controls engineers can simulate and validate industrial robot behavior in a virtual environment as well as simulate the interoperability of products, tools, robots and people.

Two areas offer significant potential for expanding robotics applications in manufacturing: product assembly and mass customization.

Theresa Houck, Executive Editor, The Journal From Rockwell Automation and Our PartnerNetwork magazine
Listen to the Podcast
8 Key Industrial Automation Trends in 2025

** Named Best Podcast 3 Consecutive Years! 2022-2024 Apex Awards of Publication Excellence.

Digitization is accelerating at an unprecedented pace, and advanced technologies are helping manufacturers create a connected, smart factory, increase efficiency and mitigate the skilled worker shortage. In this episode of Automation Chat, Executive Editor Theresa Houck discusses 8 important industrial automation trends affecting you.

Learn about smart technologies and strategies, including artificial intelligence, edge & cloud computing, digital twins, virtual reality, augmented reality, robots and cobots, connected worker technology, wireless private 5G connectivity and more.

Listen on your podcast app or on the web.

Listen Now

Product Assembly. In the past, robots didn’t have the dexterity needed to replace human hands. But with technologies such as the multi-axis arm movement, robots can replicate human dexterity. They can also be quickly reconfigured to support today’s shorter product life cycles.

Mass Customization. Modular robots, with interchangeable components for different tasks, enable mass customization in manufacturing. By allowing for on-demand product variations while maintaining mass production efficiency, they bring personalized products on a larger scale at sustainable costs.

In addition, collaborative robots, or cobots, are designed to work alongside — not replace — humans, improving efficiency and safety while simplifying complex tasks. Unlike traditional industrial robots, cobots are smaller, more affordable, easier to program, and ideal for applications like welding and assembly.

7. Workforce Development & Technologies to Mitigate Skills Gaps

Industrial firms are grappling with a significant shortage of skilled workers. To address this challenge, they’re implementing a multifaceted approach, leveraging technology and innovative methods to upskill their existing workforce and automate/augment processes to mitigate the labor gap.

Some of the ways companies are developing their employees include the following:

  • Upskilling Programs — providing workers with training in advanced manufacturing technologies and processes. This allows employees to be involved in the company’s long-term goals and provides a level of transparency, trust and loyalty.
  • Public-private Collaborations — developing collaborations between educational institutions and industry businesses to develop training programs.
  • Apprenticeships — offering technical skill development and career advancement through intensive, multiyear-long programs to help fill skills gaps and attract qualified workers.
Connected Worker Solution Boosts Efficiency, Addresses Skilled Worker Shortage

Plex, by Rockwell Automation, offers the Plex Connected Worker solution to help users enhance productivity, quality and safety on the shop floor. It provides advanced digital tools to retain, attract and reskill workers, empowering them with real-time guidance, visual aids and multimedia content to improve comprehension and reduce errors.

The connected worker capabilities are embedded within Plex’s Manufacturing Execution System (MES), providing a single source for optimizing productivity without the need for multiple subscriptions. The solution also benefits from the broader Rockwell Automation portfolio through its hardware and software offerings.

Learn more.

Get Started

In addition, connected worker technology

provides employees with mobile access to information and control systems traditionally confined to control rooms. Using smartphones, tablets and smart glasses with integrated cameras and sensors, connected worker technology is becoming an integral part of production in real time to improve their efficiency and responsiveness.

The decreasing cost of consumer devices and expanding range of commercial off-the-shelf technologies such as voice and video headsets, smart glasses and VR devices makes this technology more accessible. These worker productivity enhancing resources can include:

  • Access to manuals anywhere.
  • Equipment identification and lookup.
  • Real-time superimposed data.
  • Audio and visual links to subject matter experts.
  • Access to production availability information.

8. Sustainable Manufacturing

Manufacturers globally are working to reduce their carbon footprint through operational efficiency, energy-efficient systems, material recycling and more. Implementing environmental, social, and governance (ESG) strategies remains a significant challenge, exacerbated by regulations, the skilled worker shortage and supply chain disruptions.

This can require costs such as equipment upgrades and installation, facility assessments by environmental engineers, emissions monitoring, data-management systems and employee training. Automation technologies such as AI and additive manufacturing are helping firms reduce waste or deploy lean manufacturing methods for continuous improvement. In addition, by helping increase efficiency, robotics will play a key role in advancing green initiatives.

Additive manufacturing, also known as 3D printing, creates objects by adding layers one at a time. It’s more commonly becoming an important tool for sustainable operations because it enables the creation of complex, custom parts with lower material waste.

In addition, users can manage the build process, material handling and post-processing steps. It allows for the seamless integration of automated processes throughout the entire production cycle, from design to manufacturing. And it boosts efficiency.

It’s important to know that companies don’t have to go “all in” with automation immediately to see sustainability benefits. Start small and increase actions as resources allow.

Change is Constant

Manufacturers and producers continue to connect equipment and devices using IIoT, AI and data analytics to build smart factories and mitigate the skilled labor shortage, and this will continue. Even though technology adoption is inevitable, it doesn’t always translate into all-at-once processes. It requires ongoing improvements across various domains, such as business requirements, talent acquisition, workforce culture and the market landscape.

 

Like this article? Sign up for the digital magazine

(4X/year) and e-newsletter from The Journal From Rockwell Automation and Our PartnerNetwork.

 

 

 

The Journal From Rockwell Automation and Our PartnerNetwork™ is published by Endeavor Business Media.

Topics: The Journal Digital Transformation Industrial Analytics Industrial Automation & Control Industrial Maintenance & Support Artificial intelligence Solutions for OEMs Network Security & Infrastructure Connection Devices Sensors & Switches Programmable Controllers FactoryTalk DesignSuite FactoryTalk Twin Studio FactoryTalk Optix

You may also be interested in

Loading
Loading
Loading
Loading
  1. Chevron LeftChevron Left Rockwell Automation Home Chevron RightChevron Right
  2. Chevron LeftChevron Left Com... Chevron RightChevron Right
  3. Chevron LeftChevron Left News Chevron RightChevron Right
  4. Chevron LeftChevron Left The Journal Chevron RightChevron Right
  5. Chevron LeftChevron Left 8 Key Industrial Automation Trends in 2025 Chevron RightChevron Right
Please update your cookie preferences to continue.
This feature requires cookies to enhance your experience. Please update your preferences to allow for these cookies:
  • Social Media Cookies
  • Functional Cookies
  • Performance Cookies
  • Marketing Cookies
  • All Cookies
You can update your preferences at any time. For more information please see our Privacy Policy
CloseClose