Technology is improving every facet of the modern manufacturing industry – but it is also introducing new challenges. As this traditionally physical field becomes more reliant on IT to improve productivity and reduce costs, cracks are starting to show that could set companies back from achieving their goals. It is essential to address these early. Fortunately, there are a few easy strategies that can help prevent technology from becoming more of a burden than a benefit.
The 5 Biggest IT Challenges in the Manufacturing Industry Right Now
1. Platform Integration
Manufacturing companies often utilize a wide range of IT platforms designed to handle different aspects of their operations. Each works well independently, but they may not integrate smoothly into a single cohesive workflow. These disparate systems can create inefficiencies, data silos, and a lack of coordination that negatively impact productivity.
2. Lack of Real-Time Data
Accurate, timely data is crucial for manufacturers, allowing them to monitor and adjust production processes in real-time. In particular, it’s essential for identifying bottlenecks, optimizing machine usages, and improving supply chain performance. But collecting and storing this information can be difficult. Without access to real-time insights, companies are unable to react to changes quickly – potentially leading to downtime and higher costs.
3. Regulatory Compliance
Traditionally, manufacturing firms have had their own set of regulations to tackle. But the introduction of more data-based practices means they now must concern themselves with cybersecurity laws as well. Many workers in this industry aren’t familiar with the intricacies of IT compliance, leaving the company open to fines and other penalties.
4. Operational Technology (OT) Vulnerabilities
One of the hardest technological challenges faced by manufacturers is the unique blend of IT and OT that these companies use. It is one thing to install antivirus software and educate staff about safe data handling practices – but attempting to secure OT is an entirely separate issue. Because these two systems are often tightly interwoven, a vulnerability within one could significantly disrupt the other.
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5. Legacy Systems and Modern Software Working Side-by-Side
Many companies still use older “Legacy systems”, which were not designed with modern digital technologies in mind. These are often slow, inefficient, and do not integrate well with newer solutions. Often, the end result is a technological divide within the company – legacy systems work alongside, but never directly with, modern programs. This disparity reduces efficiency and breaks up workflows, slowing down production.
Effective IT Solutions for the Manufacturing Industry
These manufacturing IT solutions can help firms address the aforementioned problems and ensure continued productivity:
A Stronger Strategy and Better Data Management
One of the main reasons platforms become disconnected is a weak IT strategy that does not keep technology aligned with organizational needs. Involve IT leaders in the firm’s planning process, and develop a plan that takes into account which solutions will be needed. This allows them to prepare ahead of time, choosing tools that integrate more easily and provide value to the company.
Better Data Management Practices
Strong data management practices are crucial for preventing silos and ensuring accuracy and accessibility. One potential solution is cloud storage, which centralizes management regardless of location or currently used systems. By keeping all data in one place, firms make it easier to access and verify – preventing duplicates and inaccuracies in the process.
Another essential tool is AI-powered data analytics. Rather than waiting for information and then reacting, companies can get one step ahead by predicting future trends based on past behavior. This significantly improves supply chain management by allowing firms to prepare for likely outcomes that have not yet occurred, reducing downtime and handing them a competitive advantage.
Manufacturing IT Support
Compliance requirements are almost impossible for companies to track on their own, but it is not hopeless. In manufacturing, IT support and consultancy services are becoming more popular than ever as a means of obtaining expertise that would otherwise be unattainable. Providers who specialize in this field hold a deep understanding of the obligations firms must meet, and can provide necessary guidance.
Network Segmentation and Security
OT is often difficult to secure – so the best way to protect it is by preventing it from ever being accessed. Network security solutions such as next-generation firewalls, strong patch management practices, and strict access control will reduce the risk of threat actors breaching the business to begin with. Segmentation – breaking the network up into smaller pieces that are easily isolated – helps prevent lateral movement in the event that a breach does occur, making it even less likely that OT systems will be attacked.
Phased Upgrades and Cloud Solutions
Legacy technology holds more risk than simply inefficiencies and integration challenges – it can be dangerous due to unpatched vulnerabilities. For these reasons, the best solution for manufacturing firms is to replace them entirely. Concerns about cost and downtime can be addressed by implementing a phased approach that focuses on the most critical upgrades first. These include:
- Systems that could jeopardize security
- Systems that could most benefit from smoother integration with existing modern technology
- Systems that are already creating inefficiencies
One of the most effective IT solutions for the manufacturing industry is cloud computing. In addition to the data management benefits mentioned above, it modernizes systems without requiring expensive upgrades or complex integrations. In this way, firms can leverage updated technology while saving time and money.
Manufacturing IT Solutions That Create Real Impact
There are many IT challenges in the manufacturing industry that may damage productivity and security if given the chance. However, they can be overcome. A few carefully implemented solutions can create a big impact with little investment. This allows firms to minimize downtime, close skill gaps, improve efficiency, and improve manufacturing processes.
If the manufacturing IT solutions listed here aren’t sufficient, don’t fear. Ascentient is experienced with your industry, providing regular insights and top-tier services to help you maintain seamless operations. Read about some of the most popular tech trends in manufacturing if you need more advice.