Control systems + automation
Four critical cost areas, annually $6.1 million in operational agility and resilience losses Inflexible hardware systems hinder responsiveness to market shifts, as 77.4% require physical modifications for functionality updates, and multiple vendor platforms create integration complexity. Modification costs range from $25K to $50K per hour, rising to $250K/hour for $1 billion + companies. $2.28 million in optimisation and efficiency costs Maintenance burdens, downtime, and talent gaps grow as hardware complexity drives operational inefficiencies. Companies manage, on average, two to 10 different industrial systems; 29% deploy 10+ hardware platforms, each with unique management requirements. $1.2 million in preventable quality failure and costly data maintenance Proprietary systems create data silos and limit integration. Only 28% of companies access real-time insights; half report that 20 to 39% of critical data isn’t available in real time. $1.7 million in sustainability and compliance costs Regulatory changes demand costly hardware retrofits, driving up compliance expenses. Anna Ahrens, Principal analyst at Omdia, adds: “In response to mounting pressures, industrial leaders are deploying tactical solutions to sustain their core priorities for growth, competitiveness, and trust. In a world where product lifecycles shrink, supply chains fracture, and talent gaps widen, agility and flexibility are key to survival. Every quarter a business
delays addressing the cost of closed automation ecosystems is another $1 million+ in lost value: money that could be reinvested in growth and innovation.” Methodology The research, conducted by Omdia, included 10 C-suite interviews across industries (Oil & Gas, Food and Beverage, Water and Wastewater, Metals, Other Manufacturing), as well as a global quantitative survey with 320 participants in Energy and Chemicals, Manufacturing, Mining, Metals and Minerals, Warehousing and Water, Wastewater and Waste. The study was conducted in September/October 2025. By decoupling software from hardware, manufacturers gain the flexibility to integrate multi-vendor systems and adapt quickly to market shifts.
For more information visit: www.se.com
Control systems + automation: Products + services
Sharing solutions for smart manufacturing
Global education online MESA also runs a Global Education Programme (GEP) which helps manufacturers manage their digital transformation and grow their capabilities in Manufacturing Operations Management (MOM) and Manufacturing Execution Systems (MES), which have become foundational to operational excellence. MESA recognises that many manufacturers
The manufacturing industry has always been resilient, but there’s no denying that this moment feels especially challenging. Around the globe, organisations are navigating tighter margins, evolving supply chains, and difficult workforce realities. Teams are being asked to do more with less, while still maintaining quality, efficiency, and innovation. In many cases, roles are shifting as companies rethink how work gets done and where to focus limited resources. What’s becoming clear is that these challenges signal a long- term shift, not a temporary disruption. Manufacturers that continue to invest in knowledge, skills, and smarter ways of working are better positioned to adapt and compete. Those that isolate or delay progress risk falling behind. MESA International (the Manufacturing Enterprise Solutions Association) exists to help manufacturers navigate this kind of change by connecting professionals to proven best practices, peer insights, and practical guidance for smart manufacturing adoption. For manufacturers feeling the pressure to adapt but not keen to navigate these challenges alone, MESA invites you to explore the MESA community.
MESA offers members the chance to learn from their peers about smart manufacturing solutions.
struggle with digital transformation initiatives, not due to technology but because teams lack a shared, standards-based understanding of how MOM systems should be designed, implemented, and sustained. MESA training courses are designed to help manufacturers, solution providers, and consultants establish a common language and competency baseline for successful MOM programmes. Whether you are planning a new MES initiative, scaling smart manufacturing, or building internal capability across IT and Operations, MESA’s GEP can help you reduce risk, improve outcomes, and accelerate value realisation.
For more information visit: www.mesa.org
FEBRUARY 2026 Electricity + Control
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