Five Current Challenges Preventing Real-Time Visibility in Connected Manufacturing

Transforming traditional production environments into agile, data-driven ecosystems is the goal for many manufacturers. Known as “connected manufacturing,” this approach incorporates machines, technology systems, people and data into real-time operational ecosystems, replacing siloed, manual workflows. When executed successfully, leadership has the visibility needed to make precise, proactive decisions across the entire supply chain.

However, many factories still struggle with disconnected workflows, manual processes and fragmented operational data. According to a 2024 study from Zebra Technologies, a provider of enterprise data capture and visibility technology, although manufacturers say digital transformation is a strategic priority, achieving a fully connected manufacturing environment remains elusive. Visibility is key to optimizing efficiency, productivity, and quality on the plant floor, but only 16% of manufacturing leaders globally report that they have real-time, work-in-progress (WIP) monitoring across the entire manufacturing process.

Barriers often limit visibility across production, inventory and assets, but once eliminated, manufacturers can create a foundation for automation, operational excellence and future AI initiatives.

Manufacturers generate large amounts of data, but not all of it necessarily translates into operational visibility. Systems such as ERP, warehouse management and manufacturing execution systems often operate independently, creating fragmented environments that make it difficult to develop a complete view of operations.

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