Rockwell Automation Report Reveals 93% of Manufacturers Have Adopted MES, but Only 23% Achieve Full
Time:2026-07-15 Browse: 0
Rockwell Automation has released a new industry insights report highlighting the current status of Manufacturing Execution System (MES) adoption and enterprise-scale deployment among global manufacturers. The report shows that while MES technology has become widely implemented across the manufacturing industry, many companies are still facing challenges in system integration, data utilization, and digital transformation scalability.
The report, titled Enterprise-Scale MES Deployment, surveyed 1,560 manufacturing and industrial operations decision-makers across 17 major manufacturing countries and regions. The findings indicate that MES adoption is no longer the primary challenge for manufacturers. Instead, companies are now focusing on how to expand MES applications across multiple production sites and maximize business value through deeper integration.
MES Adoption Is High, but Enterprise-Wide Deployment Remains Limited
According to the report, 93% of manufacturers have deployed MES in at least one manufacturing facility. However, only 28% of companies have successfully implemented MES across their entire enterprise.
Furthermore, only 23% of manufacturers reported that their MES platforms are fully integrated with key business and operational systems, including Enterprise Resource Planning (ERP), Product Lifecycle Management (PLM), quality management systems, and Operational Technology (OT) platforms.
Many manufacturers continue to operate with disconnected systems, creating challenges in data sharing, production visibility, and operational decision-making. These limitations prevent companies from achieving the full value of their digital transformation investments.
System Integration Becomes the Key Challenge for MES Expansion
The report identifies integration capability as one of the most important factors influencing MES purchasing decisions. Around 44% of manufacturers consider integration capabilities a top priority when selecting MES solutions.
At the same time, integration remains the biggest obstacle during manufacturing modernization projects. About 33% of respondents stated that MES-related data integration is one of their major challenges.
As factories become more connected and production environments become increasingly complex, manufacturers need MES solutions that can communicate effectively with enterprise software, automation systems, industrial equipment, and cloud platforms.
AI Adoption Is Growing, but Data Readiness Remains a Barrier
Artificial intelligence is expected to play a larger role in manufacturing operations. Manufacturers surveyed in the report predict that AI-supported processes will increase from current levels to 42% within the next year and reach 54% by 2030.
However, many organizations still face challenges in preparing their data infrastructure. Approximately 43% of companies indicated that they are not yet effectively using the data they have collected.
Since high-quality industrial data is essential for AI-driven optimization, predictive analytics, and intelligent automation, improving data integration and accessibility has become a critical priority for manufacturers.
Manufacturing Security and Operational Resilience Influence MES Decisions
Cybersecurity and operational resilience are becoming increasingly important considerations for industrial digitalization projects.
The report found that 46% of manufacturers experienced cybersecurity incidents within the previous year. Meanwhile, 43% of respondents identified security and compliance as key factors when selecting MES solutions, making it the second most important purchasing consideration.
With increasing connectivity between factory equipment, enterprise systems, and cloud platforms, manufacturers are placing greater emphasis on secure architectures that can support reliable production operations.
Rockwell Automation Supports Scalable MES Deployment Through Plex Platform
Rockwell Automation highlighted that manufacturers are increasingly using its MES technologies to expand digital manufacturing capabilities across multiple production locations.
One example is Kumi North America, a Tier 1 automotive supplier specializing in automotive interior plastic components and assembly products. The company began deploying Rockwell Automation’s Plex system in 2008 and has gradually expanded its use across manufacturing facilities in the United States and Canada.
Recently, Kumi North America further extended its digital manufacturing capabilities by introducing Plex MES Automation and Orchestration (MES A&O) to improve production coordination and operational efficiency.
Paul Andrews, System Assistant Vice President at Kumi North America, explained that before implementing Plex, different operations lacked effective coordination and some manufacturing sites had no software systems in place. The company has continued expanding Plex deployment as its business grows.
MES Is Evolving from Production Tracking to Enterprise Intelligence
Rockwell Automation stated that MES technology is moving beyond traditional production monitoring and becoming a foundation for broader enterprise operations, including quality improvement, workforce productivity enhancement, supply chain forecasting, and AI-driven manufacturing optimization.
Anthony Murphy, Vice President of Product Management at Rockwell Automation, noted that the main challenge for manufacturers is no longer adopting MES, but scaling it effectively across the enterprise.
By connecting production processes, business systems, and industrial data sources, manufacturers can create a stronger foundation for advanced analytics and artificial intelligence applications.
Global Manufacturers Shift Focus Toward MES Scalability
The latest Rockwell Automation report demonstrates that MES adoption has entered a new stage. Manufacturers are increasingly focused on achieving enterprise-wide deployment, improving system connectivity, and unlocking greater value from existing digital investments.
As smart manufacturing continues to develop, scalable MES platforms, industrial data integration, cybersecurity protection, and AI-ready infrastructure will become essential components of future manufacturing strategies.
For industrial automation companies and manufacturing enterprises, the ability to connect factory operations with enterprise-level digital systems will play a key role in improving efficiency, flexibility, and long-term competitiveness.
