My co-founder and I founded MontBlancAI about 2 years ago. In that time, we’ve attended over 10 conferences and engaged in numerous conversations with manufacturing professionals. One recurring theme in these discussions is the significant skepticism surrounding software in manufacturing.
In these conversations, it became clear that the skepticism manufacturing professionals have toward software is often justified. One individual we spoke to summarized the challenges perfectly.
Most of us who have been around for a while see the pattern that software rarely delivers as much as it promises. ERP systems need an army of planners, documentation control systems make it clunky to update or change procedures, and process monitoring systems often have interlocks which require engineers on shift to override when they trigger erroneously.
Furthermore, with software as a service, many software subscriptions require tens of thousands in annual fees. I’ve seen companies spend $60k on software that made promises of reducing inventory and improving on time delivery. In the end, they would have been better off not getting the software and instead refreshing or replacing some of their equipment which was constantly breaking down
Though skepticism about software in manufacturing is understandable, there are undeniable benefits to implementing the right digital solutions in manufacturing facilities. This article will explore both sides: the reasons behind this skepticism and the advantages of embracing software. By the end, you’ll have a clearer understanding of how to approach digitalization in your own operations, navigating the challenges while leveraging its potential to drive efficiency, innovation, and growth. The goal is to help you make informed decisions about integrating software into your manufacturing processes.
Reasons for Skepticism of Software In Manufacturing
Based on our many conversations with manufacturing professionals, below are four of the main reasons for skepticism of software in manufacturing:
1. Overpromising and Underdelivering
Many professionals feel that software often falls short of the ambitious claims made by vendors, promising major gains that don’t materialize in practice. While disappointing results alone can be frustrating, this becomes a bigger issue when combined with the second challenge: complexity.
2. Complexity and Resource Demand
ERP systems and other platforms frequently require large teams or specialists to manage, making the implementation process both overwhelming and costly, adding to the frustration.
3. Clunky Processes
Some software, particularly documentation control systems, complicates routine tasks such as updating procedures, making operations inefficient and adding unnecessary friction to everyday tasks.
4. High Costs with Uncertain ROI
The significant cost of software subscriptions—often tens of thousands of dollars annually—doesn’t always justify the investment. Promises like reducing inventory and improving delivery times often fail to materialize, leaving manufacturers questioning whether the cost was worth it.
Misconceptions about software for manufacturing companies
Before we dive into how modern software addresses common concerns, it’s crucial to clarify the nature of software itself. From our many discussions with industry professionals, it’s clear that many believe all software solutions are essentially the same—but that’s far from the truth.
All manufacturing software is hard to use
Different types of software serve distinct purposes in manufacturing, and not all are designed to address the same challenges. In fact, I’ve already written an article outlining various types of manufacturing software and how each can optimize specific tasks in the manufacturing process.
For example, while ERP systems are typically more complex in terms of setup, integration, and ease of use, MES software, such as our production monitoring tool, operates differently. MES tools ingest data directly from machine PLCs and present users with relevant information that helps them better understand what’s happening on the plant floor. This simplicity makes MES software a more streamlined solution for real-time insights, without the heavy complexity of an ERP system.
Software is Only for Large Companies
Many believe that manufacturing software is only necessary or beneficial for large enterprises. In reality, modern software solutions can be scaled and customized for small and medium-sized manufacturers, offering significant value regardless of company size.
A small custom metal fabrication shop might think they don’t need software, but a simple MES solution can help them track production cycles and optimize resource allocation. For example, using low-cost production monitoring tools allows small businesses to automate processes without the expense of a full ERP system.
Software Automatically Solves All Problems
There’s also often an expectation that implementing software will immediately fix all operational issues. However, manufacturing software requires proper planning, integration, and ongoing optimization to truly enhance manufacturing processes.
More over, it’s essential to understand the different types of manufacturing software that exist, to properly understand how each type of software can help with different tasks in a manufacturing plant.
A manufacturer might install an ERP system expecting immediate benefits, but without aligning the software with their unique workflows and training their team, they may see limited results. For instance, companies in the food industry may require additional customization to address specific compliance needs
Software Implementation Always Disrupts Operations
Some believe that adopting new software will lead to significant downtime and disruption.
Today, many software solutions offer phased implementations or pilot programs that minimize disruption and allow for smooth integration into existing operations.
A medium-sized automotive parts manufacturer may fear that adopting new software will shut down production for weeks. However, many software vendors offer phased rollouts or pilot projects where, for example, they implement the software in one production line first before a full-scale launch, ensuring minimal disruption.
Together, these misconceptions contribute to the skepticism surrounding software in manufacturing companies. Understanding the root of these misconceptions—such as fears about complexity, disruptions, and costs—helps address the concerns manufacturers may have. By clarifying the specific roles that different types of software play and providing real-world examples of how software can be implemented without disruption, businesses can begin to overcome this skepticism and see the tangible benefits software offers.
The (most underrated) benefits of software
Software truly can help manufacturers. A quick search for terms like “the benefits of software in manufacturing” will reveal countless articles highlighting its advantages, from streamlining operations and reducing costs to enhancing production efficiency and improving quality control.
These benefits are widely recognized across the industry, and while skepticism persists, the value of implementing software in manufacturing processes is well-documented and supported by numerous case studies and expert insights.
One of the most underrated yet powerful advantages of software in manufacturing is the ability to search for information instantly.
Before the internet changed all of our daily lives, finding information could take hours or even days. For example, if you were looking for a quote in a specific book, the process would require a trip to the library, endless wandering through shelves, and tedious time spent flipping through pages.
Today, Google has made this process nearly instantaneous.
The time we each have been able to save thanks to this ability to search instantly has translated into invaluable productivity increases.
For example, instead of spending so much time wandering through library halls, we can instead use that saved time for more valuable tasks like advancing professional skills, focusing on personal growth, or even hanging out with family and friends.
Now think about all of the things you could do in a factory if you didn’t have to spend hours searching for maintenance logs, batch numbers, or quality control reports.
For example, instead of wasting so much time manually searching for the things above, you could:
- Focus on Process Improvement: Spend more time identifying bottlenecks and optimizing workflows.
- Increase Preventive Maintenance: Proactively monitor equipment to prevent breakdowns, improving uptime.
- Enhance Quality Control: Allocate more time to analyzing product quality trends, leading to fewer defects.
- Boost Employee Training: Train operators in new skills or technology that drive efficiency
- Reduce Downtime: Quickly address issues, ensuring smoother production flow.
Full disclosure, I am not a manufacturing professional. I asked ChatGPT to help me come up with things manufacturing professionals could do instead of having to spend endless hours searching for batch numbers or quality control reports. This is what ChatGPT came up with.
As a manufacturing expert, you probably have a better understanding of what tasks would benefit most from this time saved. Software can help free up time for whatever tasks you know matter most.
The Impact of Digital Search in Manufacturing
The ability to search using software wouldn’t just help you save time for tasks that matter most to you.
The integration of software doesn’t just change how data is stored; it transforms how that data is accessed and utilized across the entire production lifecycle. Here are some key areas where search functionality can drive higher efficiencies and improvements:
1. Enhanced Traceability and Compliance
In industries where traceability is crucial, such as pharmaceuticals, food and beverage, and aerospace, the ability to search for real-time data ensures regulatory compliance.
Software in manufacturing allows operators to access product history instantly, ensuring they can trace a product’s origins, components, and process steps without delays. The time saved, coupled with the reduction in human error, is invaluable in maintaining both quality and compliance.
2. Streamlined Maintenance and Downtime Reduction
Traditional maintenance strategies often relied on time-based or reactive approaches, which can be inefficient and costly.
Software in manufacturing, particularly when combined with IoT, allows companies to leverage predictive maintenance. Searchable data from sensors monitoring machinery can predict when equipment is likely to fail, reducing unplanned downtime.
Maintenance teams can quickly locate this information and act proactively, resulting in significant cost savings and operational efficiency.
3. Faster Decision-Making and Problem-Solving
In the fast-paced world of manufacturing, decisions need to be made swiftly and accurately. Software enables real-time search across current and historical data, empowering managers to make informed decisions in minutes rather than hours.
Whether it’s adjusting production schedules, addressing quality issues, or navigating supply chain disruptions, having searchable, up-to-date information speeds up critical decision-making.
4. Knowledge Retention and Transfer
Retaining institutional knowledge has always been a challenge in manufacturing. As experienced workers retire, valuable know-how risks being lost. With software, knowledge retention can be significantly improved because operational procedures, troubleshooting guides, and training materials are digitized and easily searchable.
New employees can access this knowledge base quickly, shortening training periods and reducing the likelihood of errors.
5. Supply Chain Optimization
Supply chain management is complex and highly reliant on timely, accurate information. Software enhances visibility across the entire supply chain, allowing operators to search and retrieve real-time data on inventory, suppliers, and production timelines.
This not only reduces the risk of delays and shortages but also allows for more strategic decision-making, such as optimizing order quantities or finding alternative suppliers during disruptions.
6. Enhanced Collaboration Across Teams
Manufacturing involves coordination between multiple teams, including design, production, and quality control. Software breaks down silos and provides a centralized, searchable repository of data.
Teams can search for and share information easily, leading to improved collaboration and faster problem resolution. Whether it’s sharing data on a production run or accessing quality metrics, digital search ensures everyone is on the same page.
7. Data-Driven Innovation
Software in manufacturing doesn’t just improve current processes; it fosters innovation. Manufacturers generate enormous amounts of data daily, and the ability to search through this data allows for deeper insights and opportunities for innovation.
Whether it’s identifying trends in machine performance, optimizing production workflows, or improving product design, searchable data can empower companies to innovate continuously.
The Broader ROI of Software in Manufacturing
The benefits of software in manufacturing extend beyond search functionality. The return on investment (ROI) for digitalization includes gains in productivity, cost savings, and product quality. These benefits are well documented.
For this article, I wanted to focus on search because it is one underrated, yet essential advantages of using software in manufacturing.
Conclusion
Search functionality is an often overlooked yet incredibly impactful benefit of digitalization in the manufacturing industry. The ability to quickly retrieve and analyze data can streamline operations, improve decision-making, and foster innovation.
Software in manufacturing isn’t just about automating tasks—it’s about transforming the way information is accessed and used to create smarter, more agile manufacturing systems.
As digitalization continues to evolve, those manufacturers who harness the power of search and other capabilities offered by software in manufacturing will be better positioned to thrive in an increasingly competitive and complex industry.
