93% of Manufacturers Use MES, But Only 23% Scale It Fully

Most manufacturers can't integrate their production software

Manufacturing execution systems have achieved near-universal adoption, but the vast majority of companies struggle to deploy them consistently across their operations, according to research released by Rockwell Automation.

The automation technology provider surveyed 1,560 manufacturing and industrial professionals across 17 countries and found that 93% have MES running in at least one facility. Yet only 23% have fully integrated these systems across all their sites, leaving most organizations with fragmented visibility into production processes.

MES platforms monitor, track, document and control how raw materials become finished goods on factory floors. The integration gap represents a critical vulnerability as manufacturers face mounting pressure from AI adoption timelines and cybersecurity risks.

Why it matters

Disconnected production systems prevent manufacturers from accessing the unified data required to deploy AI tools effectively or respond to supply chain disruptions in real time. With more than half of manufacturing processes expected to incorporate AI support by 2030, companies that can't consolidate their operational data risk falling behind competitors who can leverage machine learning for quality control, predictive maintenance, and demand forecasting.

Integration tops buying priorities

Approximately 44% of survey participants identified integration as the most important factor in their MES purchasing decisions, according to the report. The challenge also shapes modernization strategies as companies attempt to reach broader digital maturity.

"With integration ranking as both the top buying requirement and the leading modernization challenge, organizations risk leaving significant value on the table if disconnected systems and underutilized data go unaddressed," said Lorenzo Veronesi, associate research director at IDC, which contributed to the research.

The data utilization problem runs deep: roughly 43% of surveyed participants reported they are not effectively using the production data they collect, even as AI capabilities advance rapidly.

Early successes show ROI potential

Some manufacturers have achieved meaningful results from integrated MES deployments. Automotive supplier Kumi North America has expanded Rockwell's Plex smart manufacturing software across facilities in the United States and Canada since initially deploying in 2008.

"Before Plex, our operations struggled to synch and some locations didn't have any software," said Paul Andrews, assistant vice president of systems at Kumi North America.

Custom rubber manufacturer Moldtech implemented MES over six months and reported immediate impact. In the first quarter of 2025, the company reduced scrap costs by 50%, improved efficiency by 20%, and saved $25,000 through real-time inventory levels and live production metrics.

"We have live scrap reporting available to us now, allowing us to know exactly what impact our scrap will have on month-end bottom line," said Moldtech President Edward Halady.

Seven steps to scale effectively

Rockwell recommended a framework for successful MES scaling: standardize systems across sites, prioritize integration from the start, align ownership across functions, convert data into operational insight, build AI-ready operations, embed system resiliency, and empower employees to operate differently.

Anthony Murphy, vice president of product management at Rockwell, noted that MES has evolved from basic production tracking to delivering operational insights across quality management, worker productivity, and supply chain forecasting.

"Manufacturers winning the race are not doing more than the rest, they're just doing more together," Murphy said.

The findings were first reported by Manufacturing Dive based on Rockwell Automation's survey data and report released Tuesday.