Manufacturers across Europe are navigating a landscape defined by complexity, disruption, and opportunity. According to Rockwell Automation’s 10th Annual State of Smart Manufacturing Report, 81% of global manufacturers are accelerating digital transformation initiatives to address both external market demands and internal inefficiencies. In the DACH region, this momentum is particularly strong: 95% of surveyed companies have already invested or plan to invest in AI, machine learning, or generative AI within the next five years.
These figures reflect a clear shift in priorities. Manufacturers are no longer just automating; they’re redesigning how machines are conceived, tested, and deployed. The goal is to reduce development time, minimize risk, and improve performance before a single part is ordered. Traditional workflows, often siloed and manual, are no longer sufficient to meet the pace and complexity of these modern production requirements.
Engineering Collaboration in the Age of AI
Digital design is no longer only about efficiency but about enabling new possibilities. By reusing existing engineering data and integrating AI-powered assistants, teams can automate routine tasks, accelerate programming, and reduce design errors.
Automated testing through Software Development Kits (SDKs) and Continuous Integration and Continuous Deployment (CI/CD) workflows allows engineers to validate logic and performance early before any hardware is ordered. This reduces risk, shortens development cycles, and frees up time for innovation.
A compelling example of this approach in action comes from Grenzebach, a German automation specialist serving the glass and building materials industry. By adopting digital twin technology, Grenzebach was able to simulate and validate machine behavior in virtual environments before physical deployment. This not only allowed for early detection of control issues but also enabled operators to train safely and configure production parameters optimally, which saved time, effort, and cost. Their use of simulation tools helped accelerate machine configuration for new orders and reduced the risks typically associated with prototyping and commissioning.
Simulate, Predict, and Train
It’s clear that digital engineering expands what’s possible in machine design. With digital twin tools, teams can simulate line changes, validate sequences, and detect control issues in a virtual environment before going on site. This not only reduces commissioning risk but also enables plant personnel to train safely and predict future performance.
By combining simulation with physics-informed machine learning, engineers can optimize machine behavior and anticipate issues before they occur. This proactive approach supports smarter, more resilient systems from day one.
Shaping the Future of Industrial Operations
With all this in mind, Rockwell Automation envisions a future where industrial operations are not only automated but intelligently orchestrated: driven by data, designed collaboratively, and optimized continuously. This vision is embodied in a holistic approach that integrates design, operations, logistics, and maintenance into a unified digital ecosystem.
At the heart of this transformation is the principle of “design before you build”. In the early stages of machine development, engineers can simulate, validate, and optimize system behavior in virtual environments. This reduces risk, shortens development cycles, and enables early detection of control issues. AI-assisted programming like FactoryTalk Design Studio and digital twins, such as the Emulate 3D software accelerate iteration and improve design quality, allowing teams to move from concept to deployment with greater confidence.
Operational Excellence Through Data-Driven Insights
In the operations domain, intelligent planning and optimization tools help manufacturers make faster, more informed decisions. By leveraging contextualized data and scalable analytics, teams can align production goals with real-time performance insights. This enables dynamic scheduling, predictive quality control, and continuous improvement across distributed environments. Platforms that unify data modeling and visualization, such as FactoryTalk Optix, play a key role in transforming raw operational data into actionable intelligence, supporting smarter decisions across the enterprise.
Intelligent Logistics and Maintenance
Logistics is evolving through intelligent coordination of autonomous systems and mobile robotics. These capabilities enhance flexibility on the shop floor, streamline material handling, and support scalable, distributed production environments.
Maintenance is being redefined through predictive and prescriptive strategies, supported by modern Computerized Maintenance Management Systems (CMMS), such as Fiix. These platforms serve as centralized hubs for managing asset data, scheduling maintenance tasks, and tracking equipment performance. By embedding AI that analyzes historical and real-time data to detect patterns, predict breakdowns, and recommend optimal maintenance actions, Fiix empowers teams to make smarter, faster decisions and improve overall operational resilience.
A Unified Ecosystem for Smarter Manufacturing
To bring this holistic approach to life, a CoPilot ecosystem combines cloud-based intelligence with edge-level responsiveness across all areas of industrial operations. It enables engineering teams to collaborate more effectively, reduce development risk, and unlock new levels of performance and resilience.
Ultimately, it’s not only about deploying tools, but about reshaping how industrial operations are conceived, executed, and sustained. By connecting people, processes, and technologies in smarter ways, Rockwell Automation is helping manufacturers shape a future defined by agility, innovation, and intelligent automation.
About Rockwell Automation
Rockwell Automation, Inc. (NYSE: ROK), is a global leader in industrial automation and digital transformation. We connect the imaginations of people with the potential of technology to expand what is humanly possible, making the world more productive and more sustainable. Headquartered in Milwaukee, Wisconsin, USA, Rockwell Automation employs approximately 27,000 problem solvers dedicated to our customers in more than 100 countries as of fiscal year end 2024. To learn more about how we are bringing the Connected Enterprise to life across industrial enterprises, visit www.rockwellautomation.com.
