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United States Government Accountability Office Report to the Ranking Member Committee on Health,Education,Labor and Pensions U.S.Senate TECHNOLOGY ASSESSMENT Wearable Technologies Potential Opportunities and Deployment Challenges in Manufacturing and Warehousing December 2024 GAO-25-107213 The cover image depicts workers using wearable technologies in the workplace.Workers in automotive manufacturing facilities can wear arm-support exoskeletons to reduce muscle fatigue while working on the underside of a vehicle.Workers in warehousing facilities can wear ergonomic sensors designed to detect postures or motions that could cause injury.Cover source:GAO(illustration).|GAO-25-107213 United States Government Accountability Office Highlights of GAO-25-107213,a report to the Ranking Member of the Committee on Health,Education,Labor and Pensions,U.S.Senate December 2024 TECHNOLOGY ASSESSMENT Wearable TechnologiesPotential Opportunities and Deployment Challenges in Manufacturing and Warehousing What GAO found Certain wearable technologies(wearables)may provide some benefits to workers experiencing musculoskeletal pain or discomfort,such as back pain,but GAO found limited evidence to support wearables ability to reduce injuries.GAO examined the effects on worker safety of two of the most commonly deployed wearable technologies in manufacturing and warehousing:exoskeletons and ergonomic sensors.Ergonomic sensors are designed to detect postures or motions that could cause injury.Ergonomic sensor manufacturers have self-reported case studies with improved safety outcomes.GAO,however,found limited evidence that current ergonomic sensors improve worker safety,in part because multiple factors contribute to musculoskeletal injuries and posture measurements alone may not accurately predict risk.Stakeholders have described several challenges from their past experiences deploying exoskeletons and ergonomic sensors.For example:Workers expressed concerns about the practicality of wearables.Workers aremore likely to use wearables that are comfortable and convenient for their jobs.Warehousing and manufacturing company representatives expressed that theymay prefer to deploy other injury hazard controlssuch as elimination orsubstitutionbefore considering wearables.For example,providing a lift tableto eliminate a workers need to lift objects may be more effective at preventinginjuries than using a back-support exoskeleton.Many stakeholder groups voiced concerns about data that some wearables maycollect,particularly regarding data ownership,privacy,and security.The wearables market is evolving quickly.Stakeholders told GAO they need more time to assess how well ongoing efforts address these challenges.GAO identified a set of ongoing activities that stakeholder groups(such as wearables manufacturers and companies interested in deploying wearables)are undertaking.These activities include collecting additional data on accuracy and efficacy of wearables and gathering worker feedback as wearables are deployed.Additionally,national consensus committees are currently developing standards to address these challenges.Stakeholders told GAO that continuing these activities may address current challenges and did not favor other policy actions,such as additional standards and regulations.View GAO-25-107213.For more information,contact Karen L.Howard,PhD,at(202)512-6888 or HowardKgao.gov.Why GAO did this study In 2021,musculoskeletal injuries cost employers at least$17.7 billion.Workers in manufacturing and warehousing experienced these injuries at higher rates than all of private industry.Companies are investigating wearables as one option for injury prevention.Wearables that may help reduce musculoskeletal injuries include exoskeletons,which aim to relieve strain in specific muscle groups,and ergonomic sensors,which analyze posture to identify possible injury risks.GAO was asked to assess the use of wearables in industrial workplaces and their effect on workers.This report discusses(1)the extent to which select wearable technologies affect worker safety,(2)challenges that exist for deployment of wearable technologies in the workplace,and(3)associated ongoing activities that stakeholders are currently undertaking to help address the challenges.In conducting this assessment,GAO reviewed relevant literature;interviewed federal officials,academic researchers,wearables manufacturers,private companies with experience deploying wearables,a nonprofit organization,and worker organizations;conducted two visits to sites deploying wearables;and attended a conference on ergonomics.Illustration of automotive manufacturing workers wearing arm-support exoskeletons Exoskeletons are designed to reduce muscular fatigue and injuries by providing support to specific muscle groups.Laboratory studies generally show that exoskeletons can reduce muscle strain in a controlled environment.Deployments in the workplace,however,have produced limited public studies demonstrating a reduction in worker injuries,in part due to the short duration of many field studies.This is a work of the U.S.government and is not subject to copyright protection in the United States.The published product may be reproduced and distributed in its entirety without further permission from GAO.However,because this work may contain copyrighted images or other material,permission from the copyright holder may be necessary if you wish to reproduce this material separately.Wearable Technologies GAO-25-107213 i Table of Contents Introduction.1 1 Background.4 1.1 Work-related musculoskeletal injuries and ergonomics.4 1.2 Hierarchy of controls and wearables.4 1.3 Current federal agency roles for musculoskeletal injuries and wearables.6 2 Data Gaps and Efficacy Limitations Hinder Understanding of the Effects of Wearables on Worker Safety.7 2.1 Despite gaps in current deployment data,exoskeletons show some potential to reduce injuries.7 2.2 Ergonomic sensors can provide some information but have demonstrated limited efficacy and accuracy.10 3 Deployment of Wearables Raises Several Challenges.14 3.1 Challenges raised by workers.14 3.2 Challenges raised by deploying company representatives.14 3.3 Data challenges.16 3.4 Potential future challenges.16 4 While Stakeholders Resolve Deployment Challenges,Policy Changes May Not Be Useful.18 5 Agency and Stakeholder Comments.20 Appendix I:Objectives,Scope,and Methodology.21 Appendix II:GAO Contact and Staff Acknowledgments.24 Wearable Technologies GAO-25-107213 ii Tables Table 1:Commercially available exoskeletons and their uses as reported in an online trade publication.8 Table 2:Selected activities stakeholders are undertaking,which may address deployment challenges.19 Figures Figure 1:Incidence rates of musculoskeletal injuries in manufacturing and warehousing compared to all of private industry,20212022.2 Figure 2:The hierarchy of controls to reduce or remove workplace hazards.5 Figure 3:Categorization of forward bends by the National Institute for Occupational Safety and Health.11 Figure 4:Illustration of workers in an automotive manufacturing facility wearing arm-support exoskeletons.15 Wearable Technologies GAO-25-107213 iii Abbreviations BLS Bureau of Labor Statistics MSD musculoskeletal disorder NAICS North American Industry Classification System NIOSH National Institute for Occupational Safety and Health OSHA Occupational Safety and Health Administration OSH Act Occupational Safety and Health Act of 1970 PPE personal protective equipment REBA Rapid Entire Body Assessment RULA Rapid Upper Limb Assessment SOII Survey of Occupational Injuries and Illnesses wearables wearable technologies Wearable Technologies GAO-25-107213 1 441 G St.N.W.Washington,DC 20548 IntroductionDecember 12,2024 The Honorable Bill Cassidy,M.D.Ranking Member Committee on Health,Education,Labor and Pensions United States Senate Dear Dr.Cassidy:In manufacturing and warehousing,musculoskeletal injuries are prevalent,damage workers quality of life,and are costly to employers.For these reasons,occupational health and safety professionals are looking for new ways,such as using wearable technologies,to try to reduce or prevent musculoskeletal injuries from occurring.1 According to data from the U.S.Department of Labors Bureau of Labor Statistics(BLS),manufacturing and warehousing workplaces experienced higher rates of musculoskeletal injuries that resulted in missed workdays with or without job transfer or job restriction than all private industry from 2011 through 2020.2 BLS also reported that warehouse workers experienced musculoskeletal injuries at almost five times the rate for all of private industry from 2021 through 2022(see fig.1),3 and we recently found that these injuries may be underreported by employers and workers.4 According to a 2024 assessment by a workers compensation insurance provider in the U.S.,musculoskeletal injuries cost employers at least$17.7 billion in 2021,and overexertion involving outside sources,such as lifting or carrying an object,resulted in the greatest workers compensation losses for manufacturing and warehousing.5 1The Bureau of Labor Statistics(BLS)refers to musculoskeletal injuries as musculoskeletal disorders(MSDs).MSDs include injuries and illnesses such as pinched nerves,herniated discs,sprains,strains,tears,carpal tunnel syndrome,and other connective tissue diseases and disorders when the event or exposure leading to the injury or illness is overexertion and bodily reaction,overexertion involving outside sources,or repetitive motion involving microtasks.2In this report,we use the term warehousing as a shorthand for the formal BLS category of warehousing and storage.3BLS defines industry sectors using the North American Industry Classification System(NAICS),which includes 20 broad industry sectors including warehousing and manufacturing.BLS defines private industry as businesses owned by individuals or groups of individuals.BLS reports nonfatal injury data,including MSDs,in the Survey of Occupational Injuries and Illnesses(SOII).Beginning in November 2023,BLS began releasing the SOII case characteristic and worker demographic data,which includes MSDs,biennially and so the most recent data available are from 2021 through 2022.4See GAO,Workplace Safety and Health:OSHA Should Take Steps to Better Identify and Address Ergonomic Hazards at Warehouses and Delivery Companies,GAO-24-106413(Washington,D.C.:Sept.18,2024)for additional information.5Liberty Mutual Insurance,Workplace safety indices:insights and methodology(Boston,MA:Liberty Mutual Insurance,2024).GAO did not evaluate the quality of the methodology used to calculate the cost of musculoskeletal injuries to businesses.Musculoskeletal injuries include those caused by overexertion involving outside sources,other exertions or bodily reactions,and repetitive motions involving microtasks.We use warehousing as a shorthand for Liberty Mutuals category of transport and warehousing.Wearable Technologies GAO-25-107213 2 Note:Bureau of Labor Statistics defines private industry as employment in businesses owned by individuals or groups of individuals.The private industry incidence rate includes warehousing and manufacturing.BLS quotes the following relative standard errors for each incidence rate:2.5 percent for warehousing,0.8 percent for manufacturing,and 0.5 percent for private industry.Some manufacturing and warehousing companies have begun exploring wearable technologies(wearables)as an option to help prevent musculoskeletal injuries.In our previous work,6 we found that exoskeletons and ergonomic sensors are two of the most deployed wearables to address musculoskeletal safety in manufacturing and warehousing.7 Exoskeletons are devices worn around the body to support a workers arms,legs,back,hand,or use of tools.Ergonomic sensors,types of wearable sensors also known as inertial measurement units,are compact sensors designed to detect postures or motions that could cause injury.In addition to body movements,ergonomic sensors may also monitor external factors,such as environmental noise.As these technologies develop and interest in them grows,questions persist about their effects on injury reduction.For example,we recently described how some wearables may both improve safety and have unintended safety consequences for workers.8 You asked us to assess the use of wearable technologies in industrial workplaces and their effect on workers.This report discusses(1)the extent to which select wearable technologies affect worker safety,(2)the challenges that exist for deployment of wearable technologies in the workplace,and(3)associated ongoing activities that stakeholders are currently undertaking to help address the challenges.We are focusing our discussion on exoskeletons and ergonomic 6GAO,Science&Tech Spotlight:Wearable Technologies in the Workplace,GAO-24-107303(Washington,D.C.:Mar.4,2024).7We consider a company to have deployed wearables if it has tested,piloted,or implemented wearables with its workers.8GAO-24-106413.Wearable Technologies GAO-25-107213 3 sensors deployed in the manufacturing and warehousing workplaces.See appendix I for a full discussion of the objectives,scope,and methodology.We conducted our work from January 2024 through December 2024 in accordance with all sections of GAOs Quality Assurance Framework that are relevant to technology assessments.The framework requires that we plan and perform the engagement to obtain sufficient and appropriate evidence to meet our stated objectives and to discuss any limitations to our work.We believe that the information and data obtained,and the analysis conducted,provide a reasonable basis for any findings and conclusions in this product.Wearable Technologies GAO-25-107213 4 1 Background 1.1 Work-related musculoskeletal injuries and ergonomics Work-related musculoskeletal injuries,which affect muscles,nerves,tendons,joints,cartilage,and spinal discs,can damage workers quality of life and be costly to companies.The Department of Labors BLS defines musculoskeletal injuries as those resulting from bodily reaction(e.g.,bending,climbing,crawling,reaching,and twisting),overexertion,or repetitive motion(e.g.,leaning to reach items,lifting boxes,and working overhead on assembly lines).The National Institute for Occupational Safety and Health(NIOSH)of the Department of Health and Human Services has recognized work-related musculoskeletal injuries as a type of injury since 1997.These injuries are conditions in which:(1)the work environment and performance of work contribute significantly to the injury or(2)the injury is made worse or persists longer due to work conditions.Work-related musculoskeletal injuries can affect a workers ability to perform job functions(e.g.,lifting)and enjoy activities outside of work.Work-related musculoskeletal injuries are also associated with high costs to employers through absenteeism and lost productivity,as well as increased health care,disability,and workers compensation costs.For example,according to one analysis,back-related musculoskeletal injuries were associated with the highest cost 9Liberty Mutual Insurance,Workplace safety indices.10Stakeholders can include wearables manufacturers,deploying companies,occupational health and safety professionals,worker organizations,academic researchers,to employers compared to other body part injuries.9 Although musculoskeletal injuries may develop quickly when workers are required to perform very hazardous work for many hours a day,musculoskeletal injuries can also take long periods of time before they become observable.One stakeholder pointed out that a musculoskeletal injury that results in a workers compensation claim could take 5 to 10 years to develop,and it may have already begun developing prior to the implementation of wearables or other controls.10 1.2 Hierarchy of controls and wearables Occupational health and safety professionals and ergonomists use a framework called the hierarchy of controls when considering which actions may best reduce workplace hazards or mitigate workers exposure to those hazards,including those that lead to work-related musculoskeletal injuries.NIOSH developed the hierarchy of controls as a reference for companies seeking to reduce the risk of workplace injuries.11 As shown in figure 2,NIOSH includes five levels of actions a company can take to reduce or remove hazards or mitigate exposure,listed from most to least effective(top to bottom).government agencies,and a workplace safety nonprofit institution.See appendix I for more information.11NIOSH,“About Hierarchy of Controls,”(Jul.31,2024),https:/www.cdc.gov/niosh/hierarchy-of-controls/about/index.html.Wearable Technologies GAO-25-107213 5 The five levels of actions are categorized and organized by effectiveness,but the most effective mitigations may not be the easiest to implement into existing processes.Eliminationphysical removal of the hazard at the sourceis the most effective and preferred way to mitigate risks but is best to implement at the development stage of a work process.Elimination could include automating a hazardous task so that a worker does not have to perform it.The next preferred method in the hierarchy of controls is substitutionusing a safer alternative to the hazard,such as using an automated tool instead of a manual one.Next,engineering controls involve redesigning worksuch as implementing protective barriersto isolate workers from a hazard.Administrative controls establish work practicessuch as job rotationsthat reduce the duration,frequency,or intensity of a workers exposure to a hazard.Finally,providing personal protective equipment(PPE)to minimize exposure to hazards is considered the least effective control and includes providing a worker with protective equipmentsuch as safety glassesto reduce exposure to the hazard while performing the task.PPE can be effective at reducing hazard exposures,but only when employers and workers use it correctly and consistently.Occupational health and safety professionals said they generally consider wearables as either administrative controls or PPE.Because NIOSHs hierarchy of controls considers these the least effective hazard reduction tools,companies interested in deploying wearables might choose to also consider more effective safety controls,such as elimination or substitution.Wearable Technologies GAO-25-107213 6 1.3 Current federal agency roles for musculoskeletal injuries and wearables Two federal government agenciesNIOSH of the Department of Health and Human Services and the Occupational Safety and Health Administration(OSHA)of the Department of Laborcurrently have small but important roles related to wearables in workplaces.NIOSH conducts research on and makes recommendations for the prevention of work-related injury and illness.In this role,NIOSH funds studies to assess the feasibility and long-term effects of wearables in the workplace and educates health and safety personnel about implementation of new technologies,such as wearables.NIOSH officials said that the agency does not currently test the accuracy of wearables,but it does certify other devices such as respirators.12 OSHAs mission is to ensure American workers have safe and healthful working conditions and are free from unlawful retaliation by employers.OSHA carries out this mission,in part,by setting and enforcing workplace safety and health standards.While OSHA does not have a specific standard for ergonomic hazards that cause musculoskeletal injuries,it addresses ergonomic hazards through enforcement of the general duty clause.13 We recently found,however,that OSHA rarely identifies and 12See,42 C.F.R.Part 84 for the procedures and requirements for approval of respiratory devices.13Section 5(a)(1)of the Occupational Safety and Health Act of 1970(OSH Act),known as the general duty clause,requires employers to provide a work environment free from recognized hazards that are causing or are likely to cause death or serious physical harm.29 U.S.C.654(a)(1).A specific standard OSHA issued in 2000 to protect workers from addresses ergonomic hazards at warehouses due to several challenges.We provided several recommendations to address this finding.14 OSHA also does not have standards for emerging technologies,including exoskeletons,ergonomic sensors,or other wearables.OSHA officials said they may note the use of technologies,such as wearables,that they observe while inspecting workplaces and that OSHA has not received reports of any injuries directly attributable to the use of wearables.ergonomic hazards was reviewed and disapproved by Congress under the procedures of the Congressional Review Act,5 U.S.C.802(a).Ergonomics Program,65 Fed.Reg.68,262(Nov.14,2000)was disapproved by Joint Resolution,Pub.L.No.107-5,115 Stat.7(Mar.20,2001).14GAO-24-106413.Wearable Technologies GAO-25-107213 7 2 Data Gaps and Efficacy Limitations Hinder Understanding of the Effects of Wearables on Worker SafetyCurrent data offer limited evidence demonstrating the long-term efficacy of exoskeletons and ergonomic sensors to reduce injuries and improve worker safety.Current publicly available studies we reviewed did not find definitive measurable safety results in the field from deployments of exoskeletons.Laboratory studies,however,offer encouraging data that exoskeletons can reduce muscle strain and may,over time,help prevent injuries.Ergonomic sensors can offer diagnostic information about some injury risks,but studies have not demonstrated that this information can improve worker safety due to multiple limitations,including sensor accuracy.2.1 Despite gaps in current deployment data,exoskeletons show some potential to reduce injuries 2.1.1 Principles of operation Exoskeletons are designed to reduce muscular fatigue and injuries.The exoskeleton provides support to particular muscle groups,such as the shoulders or lower back,to help reduce muscle strain.In turn,this strain reduction may reduce muscle fatigue and make workers less likely to sustain musculoskeletal injuries.Exoskeletons can be active,meaning they use battery-powered motors to assist the muscles and augment the strength of the wearer,or passive,meaning they are not battery powered and instead use springs and dampers to support the wearer(see text box).Passive and active exoskeletons Exoskeletons can be passive or active,depending on whether the system uses an onboard battery.Passive systems have springs and dampers that provide a counterforce to relieve the strain on targeted muscle groups,such as a workers shoulders.Some models include an adjustment to change the tension and provide more or less support.By contrast,active systems use battery-powered motors in the suit to adjust the level of support depending on the workers movements.For example,an active suit can vary support depending on how fast the worker moves to make a lift or bend.In general,active exoskeletons are designed for heavier-than-normal lifts,but these devices also tend to weigh and cost more.In our site visits and discussions with deploying companies,we found they predominantly used passive exoskeletons,but some stakeholders noted that active systems may be deployed more frequently outside the U.S.In particular,one manufacturer of active exoskeletons said they have deployed systems primarily in Europe and had only recently begun to expand to the U.S.market.Source:GAO(analysis and illustration).|GAO-25-107213 Wearable Technologies GAO-25-107213 8 According to our research,companies have predominantly deployed passive arm-and back-support exoskeletons in industrial workplaces.Table 1 shows the varieties of commercially available passive and active exoskeletons and some examples of their use,according to market data from one exoskeleton trade publication.According to this publications market data,the types of exoskeletons with the highest number of models on the market are arm-and back-support exoskeletons.Two companies we spoke with that had tested or deployed exoskeletons also noted they worked predominantly with arm and back exoskeletons,because of technical maturity and use cases for their industries.Table 1:Commercially available exoskeletons and their uses as reported in an online trade publication Exoskeleton type Power source Number of modelsa Use case Arm support Passive 22 Shoulder support(e.g.,underbody automotive work)Active 5 Shoulder support(e.g.,using power tools overhead)Back support Passive 37 Reduce load on back when repetitively lifting(e.g.,picking items in a warehouse)Active 13 Reduce load on back when lifting heavy objects(e.g.,heavy lifting in the logistics industry)Leg support Passive 5 Reduce load on knees when crouching and squatting(e.g.,cement laying)Active 3 Supports and aids movement of knees and hips(e.g.,lifting heavy equipment)Hand support Active 2 Grip support for repetitive tasks(e.g.,using power tools for extended periods of time)Tool support Active 2 Offload the weight of a heavy tool(e.g.,drilling overhead)Source:GAO analysis of market data from Exoskeleton Report.|GAO-25-107213 aThe number of each type of exoskeleton on the market was determined from market research from the trade publication Exoskeleton Report as of October 7,2024.Wearable Technologies GAO-25-107213 9 2.1.2 Efficacy Laboratory studies generally show that exoskeletons can reduce muscle strain,but these results have not translated in the same degree to measured safety benefitssuch as a reduction in injuriesin the field.A variety of laboratory studies have tested the ability of exoskeletons to reduce muscle strain,typically by using electrical sensors to measure muscle exertion of a prescribed series of tasks with and without the exoskeleton.According to our review of studies,researchers have measured muscle strain reductions from 7 to 87 percent when using exoskeletons.15 This large range reflects reductions in strain on the specific muscles of individual subjects recorded by sensors that measure muscle activity.Reductions also varied by exoskeleton design and activity type.Two studies saw no reduction in strain,but generally the studies we reviewed showed some strain reduction in this range.One exoskeleton researcher concurred that,according to his research and review of literature,laboratory studies generally found that exoskeletons can reduce muscle strain.Despite the encouraging laboratory results,deploying companies and researchers have found limited evidence of measurable safety results in the field.According to our literature review and conversations with stakeholders,neither laboratory nor field studies have shown definitive evidence that exoskeletons reduce injuries.As one study highlighted,the 15Our literature review identified eight laboratory studies of which six demonstrated some strain reduction.The two additional studies did not demonstrate any strain reduction.See appendix I for details on our literature review.16Sunwook Kim,Maury A.Nussbaum,and Marty Smets,Usability,User Acceptance,and Health Outcomes of Arm-magnitude of benefits seen in laboratory results may overestimate the effects in the field.Some deploying companies reported positive early signs of potential injury reduction from exoskeleton use,such as successful small trials,reduced worker discomfort,and fewer medical visits.Representatives from one of those companies,however,said their internal trials have not conclusively shown a reduction in injuries.Possible causes for the limited evidence of measurable safety results include:Limited long-term studies.Deploying companies and researchers may need more time to measure a safety outcome from exoskeletons.Ergonomic injuries develop over years,and measuring an improvement in safety can thus require years of data collection,while many existing field trials last only a month or less.In addition,researchers and deploying companies may struggle to maintain and track user participation over this extended period as workers discontinue exoskeleton use,change to work tasks that do not require an exoskeleton,or leave the company.As of February 2024,the longest field study we identified in the literature on exoskeletons followed employees at an automotive manufacturing plant over 18 months.16 While the study showed that the users of arm-support exoskeletons made fewer medical visits involving upper extremity injury or pain than those in the control group,significant participant dropout impacted the certainty of their findings.Thirty-seven Support Exoskeleton use in Automotive Assembly:An 18-Month Field Study,Journal of Occupational and Environmental Medicine,vol.64,no.3(2022),https:/doi.org/10.1097/JOM.0000000000002438.Wearable Technologies GAO-25-107213 10 percent of participants in the exoskeleton group and 38 percent of the control group left the study due to reasons such as job transfers and loss of interest.Even when companies can conduct long-term studies,they can find it difficult to isolate the effects of an exoskeleton on workers safety.Over the course of years in the workplace,workers might change job tasks that will affect their risk of injury.In addition,companies will likely implement multiple complementary safety measures,which makes it difficult to determine whether any improved safety outcome can be attributed solely to using exoskeletons.Differences in field and laboratory conditions.Results from laboratory tests do not necessarily transfer to the field due to the limitations of laboratory environments.Laboratory-based studies we reviewed tended to use participants with no experience in manufacturing or warehousing jobs,occur within highly controlled environments,and involve simulated tasks,such as lifting a box.These factors do not negate the studies findings but raise questions about how well exoskeletons might work among a more representative population or in a more dynamic warehousing or manufacturing environment.Researchers also face greater challenges when measuring the effects of exoskeletons on workers in the field.Rather than measuring muscle strain directly,researchers may need to rely on worker questionnaires on topics such as perceived comfort,fit,and job 17Kim,Nussbaum,and Smets,“Usability,User Acceptance,and Health Outcomes,”209.performance when using the exoskeleton.This may be necessary because the electrical sensors used to measure muscle strain are difficult to interpret in the field.The absence of quantitative physiological data could make it more difficult to understand the potential safety effect of exoskeletons in the field.Collecting data on usage patterns also posed a challenge to researchers.According to one study,some participants may have used their exoskeletons for a few hours a day or a couple of days per week,while others may have used their exoskeletons for the entire workday,but the researchers did not have adequate data on that usage.17 The authors noted that the absence of data on the frequency of exoskeleton use can make it difficult to quantify the benefits and limitations of the exoskeleton use for worker safety.2.2 Ergonomic sensors can provide some information but have demonstrated limited efficacy and accuracy 2.2.1 Principles of operation Ergonomic sensors measure the bodys orientation and use algorithms to analyze whether workers enter postures that might put them at risk for injury.18 Usually worn on the back,hip,or arm,one common ergonomic sensor measurement involves measuring the angle the body creates in a 18Ergonomic sensors measure acceleration,rotation,and magnetic fields to infer motion and orientation.These sensors are sometimes known as inertial measurement units.Wearable Technologies GAO-25-107213 11 forward bend at the hips(fig.3).19 Ergonomists regularly use posture as a risk factor for potential injury when analyzing job tasks.For example,it is commonly accepted that as a worker bends farther forward and assumes an increasingly non-neutral posture,the muscle strain on the lower back increases,as does the risk of musculoskeletal injury.20While worn,ergonomic sensors continually monitor and collect data on the workers posture to help infer injury risk.An ergonomist or occupational health and safety professional can analyze the ergonomic sensor data to determine to what extent and how often the worker is bending and whether this puts them at injury risk using ergonomics 19While various ergonomic sensors may measure multiple body postures(forward bend,lateral bend,twisting,etc.),we highlight the forward bend to illustrate the principle of operation.20NIOSH published a literature review evaluating the effect of workplace factors on musculoskeletal injuries and found,for example,that bending and extending into non-neutral postures generally increases injury risk.Department of Health and Human Services,NIOSH,Musculoskeletal Disorders and Workplace Factors A Critical Review of Epidemiologic calculations.21 An ergonomist can use this information to,for example,provide additional training to teach employees safer movements or modify the workspace to reduce or eliminate ergonomic risks.Some ergonomic sensors include a feature to provide real-time feedback to the worker.Evidence for Work-Related Musculoskeletal Disorders of the Neck,Upper Extremity,and Low Back,97-141(1997).21Ergonomists can use a number of calculations to assess ergonomic risk,including the Rapid Upper Limb Assessment(RULA)and the Rapid Entire Body Assessment(REBA).See Department of Health and Human Services,NIOSH,Observation-Based Posture Assessment:Review of Current Practice and Recommendations for Improvement,2014-131(2014).Wearable Technologies GAO-25-107213 12 When the sensor detects a bend beyond a certain thresholdsuch as 60 degreesthe sensor will vibrate or emit an audible sound to alert the worker about potential for injury risk due to their posture.22 Wearables manufacturers we spoke with expressed divided views on the efficacy of this real-time feedback.Some manufacturers felt the feedback provided the best tool to alert workers when they make risky movements and influence them to change their behavior.Another manufacturer said they did not include this feature because they believe workers are likely to disregard the feedback,and the manufacturer sees little evidence that real-time feedback can create lasting changes in worker behavior.Unlike exoskeletons,ergonomic sensors require extra interventionthrough data analysis and workplace modification,a real-time feedback system,or bothto potentially improve worker safety.The sensor alone does not,for example,prevent workers from bending too far or alleviate the strain of lifting in a forward bent position.Other posture analysis methods,such as when an ergonomist directly observes a task and manually measures body angles,also require extra interventionthese analyses only identify the possibility for risk of injury.Despite the need for further intervention,multiple experts noted that ergonomic sensors can help improve posture analysis by providing continuous measurement of posture over multiple days and removing bias 22Some ergonomic sensor manufacturers cited 60 degrees as the threshold their devices use to indicate increased risk.NIOSH guidance does not specify 60 degrees as a threshold of marked elevated risk but notes that risk generally increases with a more non-neutral posture.associated with human measurement and observation.2.2.2 Efficacy We found limited evidence that current ergonomic sensors can improve worker safety.While wearables manufacturers have published case studies on improved safety outcomes,these studies are proprietary and manufacturers could not provide the underlying data for us to assess their validity.23 For example,for one ergonomic sensor manufacturer,we reviewed five case studies which reported a reduction in risky bends and zero injuries over the course of 3 to 5 months.These case studies,however,lack key information required to assess the significance of their findings.For example,none of these studies reported a baseline rate of injuries before the introduction of the ergonomic sensor or used a technique such as comparing outcomes of workers in randomly assigned sensor user and control groups,which is necessary to determine the effect of the sensor on injuries.Furthermore,two deploying companies we spoke with that piloted ergonomic sensors reported they discontinued using ergonomic sensors.One warehousing company representative explained the decision to discontinue use by noting that when the company compared 6 months of data from workers using the ergonomic sensors to 6 months of data without use,the company saw no change in injury rates.In the research literature,we found six studies that assessed the 23Improved safety outcomes in these case studies include a reduction of“risky”forward bends greater than 60 degrees or a reported reduction in injuries during a pilot study.Wearable Technologies GAO-25-107213 13 performance of ergonomic sensors for measuring posture in the field.None of the studies we identified,however,connected these results to a measured safety outcome(e.g.,reduction in injuries,days off work,workers compensation claims).According to our review of available information,two explanations,discussed below,may account for the absence of measurable safety outcomes with ergonomic sensors.Multiple ergonomic factors.In its review of research on musculoskeletal disorders,NIOSH identifies factors in addition to posture,such as force and speed of a movement,that also affect musculoskeletal injury risk.Multiple ergonomics experts also pointed to the multiple factors that influence injury risk.One researcher explained that while ergonomic sensors may detect the frequency with which a worker makes a risky bend,this does not necessarily correspond to the total injury risk.Rather,one single high-force lift from a bent position may cause an injury.Given the multifaceted nature of injury risk and the short duration of studies to date,some experts highlighted the need for long-term studies to understand the extent to which ergonomic sensors can predict injuries.Longer multi-year studies could help improve understanding of which factors matter most for injury prevention,the risk thresholds for these factors,and how ergonomic sensors can affect injuries over time.At present,these studies do not exist.24Magnetometers are used in ergonomic sensors to measure Earths magnetic field to help determine orientation.Francesco Pistolesi and Beatrice Lazzerini,“Assessing the Risk Accuracy.Ergonomic sensors may not measure body posture accurately or consistently,which limits their ability predict injury.Multiple research studies and stakeholders we spoke to highlighted that accuracy can vary according to the number of sensors used(e.g.,one sensor worn on the hip vs.sensors on the arm,hip,and back)and the software algorithms used to analyze the ergonomic data.Some commercial systems use just one sensor,which studies show can limit accuracy.The industrial environments where workers use the sensors can also degrade accuracy.For example,one study found that while incorporating magnetometers into sensors can improve the accuracy,these signals can be distorted due to interference from the materials present in industrial workplaces.24 Despite these limitations,some research studies have shown the ability to improve system accuracy with improved algorithmssuch as those using machine learning.Despite these challenges,some deploying companies and other stakeholders see value in ergonomic sensors to provide diagnostic information or in applications beyond posture monitoring.For example,one research group demonstrated the ability to process data from ergonomic sensors to determine worker proximity to slip,trip,and fall risks.Additionally,some ergonomic sensor manufacturers have begun including other safety components,such as location sensors to prevent collisions with heavy machinery(e.g.,forklifts).of Low Back Pain and Injury via Inertial and Barometric Sensors,”IEEE Transactions on Industrial Informatics,vol.16,no.11(2020).Wearable Technologies GAO-25-107213 14 3 Deployment of Wearables Raises Several ChallengesAs discussed in the prior sections,companies have begun deploying wearables and gathering information on the resulting benefits and challenges.The wearables market,however,is evolving quickly and may outpace the speed of a companys deployment protocols and acquisition of data on safety effects.Stakeholders have described several challenges for wearables from experiences with initial deployments.These challenges are comfort,convenience,identifying appropriate jobs,identifying appropriate controls,limited efficacy data,data ownership,data privacy,the evolving market of wearables,and worker burdens.We have organized these challenges below by those raised by workers,those raised by deploying company representatives,those concerning data,and those that may arise in the future.3.1 Challenges raised by workers Comfort.If a wearable is not comfortable,workers will not wear it.Workers,representatives from deploying companies,and researchers consistently cited comfort as a barrier to worker use of wearables.For example,workers we spoke with said that exoskeletons can sometimes be hot and uncomfortable,particularly during summer months and periods of high humidity.Wearables also need to fit a wide range of body types,and many workers,particularly women,have cited poor fit,particularly around the chest and hips,as the reason for discontinuing voluntary use.Convenience.The accessibility of wearables and the convenience of incorporating them into existing workflows arose as an overarching challenge for workers.We found in our conversations with workers and representatives from deploying companies that workers prefer to use wearables that are easy to access,quick to put on and take off,do not impede the fluidity of their motion when performing routine work,pose minimal snag risks,and are not likely to damage the companys product.For example,Department of Defense representatives who conducted an initial deployment of arm-support exoskeletons at shipyards reported concerns with convenience as one reason for discontinuing use.Shipyard workers generally only needed the exoskeleton for short-term,highly specific tasks and found that the benefit from wearing the exoskeleton did not exceed the burdens of carrying the exoskeleton the long distance between the lockers and shipboard work areas or of wearing the exoskeleton during jobs that didnt require its support.3.2 Challenges raised by deploying company representatives Identifying appropriate jobs.Workers are more likely to use wearables appropriately matched to their job.However,identifying appropriate jobs for wearables is not always straightforward.Representatives from multiple deploying companies said that identifying jobs that would most benefit from exoskeleton use often involved considerable trial and error.For example,arm-support exoskeletons may generally match well for overhead work,but only if a worker spends the majority of their time on that job in an overhead position and not moving back and Wearable Technologies GAO-25-107213 15 forth between positions(see fig.4).Similarly,ergonomic sensors may be designed to be worn in an upright position and may not be appropriate for workers who spend significant times in alternative positions,such as lying on their back.Identifying appropriate controls.Wearables may not be the most effective control in certain circumstances(see 1.2).For example,in a warehouse setting that requires employees to repetitively bend at the hips,a lift table might be a more effective intervention than a back-support exoskeleton because the lift table reduces the need for the worker to lift rather than providing support for lifting.In contrast,a common use case for arm-support exoskeletons in automotive manufacturing is underbody workworking on the underside of a vehiclewhich cannot be easily eliminated due to the configuration of production lines.Likewise,data from ergonomic sensors,as noted above,could potentially identify job processes or environmental factors that increase risky postures.With this information,an ergonomist or health and safety professional can implement changes to the workspace through engineering controls,such Wearable Technologies GAO-25-107213 16 as redesigning a workstation,that might reduce risk.Limited efficacy data.A lack of data on injury reductions from publicly available studies,as discussed above,can make it difficult for companies to justify deployments and predict the likelihood of success when deploying wearables.Representatives we spoke to from companies deploying wearables discussed the need to justify the companys use of wearables.Limited efficacy data available for wearables,as discussed in chapter 2,can make it challenging for decision makers to decide if wearables are a cost-effective safety solution.For example,representatives from some deploying companies we spoke to did not feel that ergonomic sensors provided enough benefit on their own to justify the cost of deployment,in part due to limited efficacy data.3.3 Data challenges Data ownership.Multiple stakeholders raised concerns about the ownership of data collected from the use of wearables.For example,a representative from one deploying company we spoke to expressed concerns about data ownership and said it was unclear whether the data collected belong to the wearables manufacturer or to the deploying company as proprietary information.Additionally,officials from NIOSH said that there is an open question regarding worker access to and ownership of the data.25We also found that privacy was the concern most frequently raised by stakeholders regarding digital surveillance of workers including wearable technology as well as other tools.See GAO,Digital Surveillance of Workers:Tools,Uses,and Stakeholder Data privacy.The data that some wearables collect and store also raise privacy and security concerns.25 As we discussed in our previously issued Science&Tech Spotlight report,data on worker physiology and movements captured by monitoring devices such as ergonomic sensors can raise privacy concerns.26 For example,workers surveyed as part of a wearables pilot test cited concerns about being tracked,and stakeholders we spoke to had similar comments.We also discussed in our spotlight that data stored on wearables may be vulnerable to hackers and therefore raise data security concerns.Stakeholders told us that larger companies may be better equipped to handle this challenge than small-or medium-sized ones.3.4 Potential future challenges Evolving market.The wearables market is evolving faster than wearables assessment and deployment in warehousing and manufacturing facilities.Companies interested in deploying wearables need time to research,procure,test,approve,and then deploy the technology.As a result,wearables manufacturers may develop a new generation of their device before a deploying company has finalized the implementation protocols for the generation they are working to roll out.This increases the risk of device obsolescence.For example,a representative from one deploying company said that the first exoskeleton system they deployed in 2019 had a new model released less than a year later,and the company needed to restart Perspectives,GAO-24-107639(Washington,D.C.:Aug.28,2024).26GAO-24-107303.Wearable Technologies GAO-25-107213 17 its assessment and approval process for the new model.Worker burdens.More frequent deployment of wearables in manufacturing and warehousing workplaces may raise additional concerns in the future,such as misplaced safety burdens and punitive use.Some stakeholders expressed concerns about wearables placing the burden of safety on the worker rather than on the company to improve the safety of the workplace.According to NIOSH officials,there is a risk that some companies may use wearables to focus on changing worker behavior for non-safety goals rather than on providing a safer work environment.While we found no evidence of current punitive uses and union representatives said no issues related to wearables had been reported to them,they expressed concerns about the potential for punitive use of data collected by wearables.For example,workers may be reprimanded for performing too many risky bends in a shift.Finally,stakeholders also expressed concerns about companies exploiting wearables to drive additional worker productivity,which may reduce any safety benefits.For example,if a worker feels less fatigued due to using wearables,they may feel pressured to accomplish more of a task in a given time period,increasing risk for musculoskeletal injury due to repetitive motion.Wearable Technologies GAO-25-107213 18 4 While Stakeholders Resolve Deployment Challenges,Policy Changes May Not Be UsefulStakeholders told us that more time is needed to resolve various challenges related to wearables in the industrial workplace before policy changes,such as additional standards and regulations,may be useful.For example,national consensus committees are currently developing new consensus standards to address concerns such as safe design and manufacture,risk management,and ergonomics.Stakeholders suggested that they could continue current activities,such as exploring deployment of wearables and documenting findings,allowing the market to develop and identify the best technologies,and gathering and responding to worker feedback.As stakeholders continue their existing activities,more information may become available about challenges,concerns,and other issues that arise when deploying wearables.In addition,more time could yield additional data on the extent to which wearables improve worker safety or reduce workplace injuries.This improved understanding could help inform future decisions made by deploying companies,worker organizations,manufacturers,and federal agencies.One potential disadvantage of continuing current activities without policy intervention,however,is that it could allow wearables to enter the marketplace without safeguards to prevent data abuse or potential future punitive use.Below,we identify and describe selected ongoing activities that different stakeholders are undertaking.According to our discussions with stakeholders,these activities may address many of the challenges outlined in chapter 3.Wearable Technologies GAO-25-107213 19 Table 2:Selected activities stakeholders are undertaking,which may address deployment challenges Stakeholder group Selected activities to continue Challenges addressed Deploying companies Considering hierarchy of controls to mitigate work hazards with controls that are more effective than personal protective equipment(PPE),such as elimination,substitution,or engineering controls.Wearables may be worth using when a more effective control is not possible,which may help ensure the wearable is appropriate to the task.Identifying appropriate jobs;Identifying appropriate controls Gathering feedback from workers on concerns including comfort,ease of use,appropriateness to the task,data ownership,and policies on voluntary usage.Comfort;Convenience;Identifying appropriate jobs Evaluating safety culture.Companies that prioritize safety over productivity will likely have more successful deployment of wearables.Worker burdens Defining goals of successful deployment and developing implementation protocols.Depending on how success is defined,companies may be able to evaluate effectiveness in worker safety improvement,injuries and discomfort reduction,and worker acceptance.Identifying appropriate jobs;Limited efficacy data;Evolving market Worker organizations Gathering worker feedback as companies deploy wearables.Doing so may help ensure that wearables are comfortable and convenient and deter the punitive use of wearables by deploying companies.Comfort;Convenience;Worker burdens Monitoring company deployment of wearables may ensure that appropriate hazard controls are employed and prevent infringements on worker rights and protections.Identifying appropriate controls;Worker burdens Wearables manufacturers Gathering and providing additional data on accuracy and efficacy of devices to help deploying companies make decisions through lab-and field-based evaluations and address the current lack of data on injury reduction.Identifying appropriate jobs;Limited efficacy data Evaluating market trends to respond to company and worker feedback and refining products as appropriate,such as ensuring that wearables are comfortable,easy to use,and have data security.Evolving market;Comfort;Convenience;Data privacy;Academia Partnering with wearables manufacturers and deploying companies to conduct pilot testing and collect data on efficacy of wearables.Identifying appropriate jobs;Limited efficacy data Expanding wearables applications beyond musculoskeletal injury prevention,such as data-processing methods for ergonomic sensors to monitor hazards related to slips,trips,and falls.Identifying appropriate jobs;Identifying appropriate controls;Evolving market Federal agencies Funding research on accuracy and efficacy to help increase data on wearables and how they could be deployed in the workplace(National Institute for Occupational Safety and Health).Limited efficacy data Enforcing workplace health and safety laws may help identify problems related to deployments,such as if a company is deploying wearables as a substitute for ensuring a safe work environment(Occupational Safety and Health Administration).Worker burdens Source:GAO.|GAO-25-107213 Wearable Technologies GAO-25-107213 20 5 Agency and Stakeholder Comments We provided a draft of this report to the Departments of Health and Human Services,Labor,and Defense with a request for technical comments.We incorporated agency comments into this report as appropriate.We also provided a copy of the draft report for review and comment to stakeholders representing some of the groups identified in our discussion of ongoing activities:deploying companies,wearables manufacturers,and academic researchers.We incorporated stakeholder comments as appropriate.As agreed with your office,unless you publicly announce the contents of this report earlier,we plan no further distribution until 30 days from the report day.At that time,we will send copies of this report to the appropriate congressional committees,the relevant federal agencies,and other interested parties.This report will be available at no charge on the GAO website at https:/www.gao.gov.If you or your staff members have any questions about this report,please contact Karen L.Howard at(202)512-6888 or HowardKgao.gov.Contact points for our Offices of Congressional Relations and Public Affairs may be found on the last page of this report.GAO staff who made key contributions to this report are listed in appendix II.Sincerely,Karen L.Howard,PhD Director,Science,Technology Assessment,and Analytics Wearable Technologies GAO-25-107213 21 Appendix I:Objectives,Scope,and MethodologyObjectives We describe our scope and methodology for addressing the three objectives outlined below:1.To what extent do select wearable technologies affect worker safety?2.What challenges exist for deployment of wearable technologies in the workplace?3.What activities,if any,may help address these challenges?To address all research objectives,we conducted a literature search and reviewed key reports,peer-reviewed articles,and literature from nonprofits and wearables manufacturers.In addition,we interviewed a variety of stakeholders including federal agency officials;academic researchers;unions;nonprofits;and private companies,including those that deploy or have deployed wearables and those that manufacture wearables.We also conducted two site visits to private companies deploying wearables to speak with occupational health and safety personnel and workers who use wearables and attended the Applied Ergonomics Societys 2024 conference.Scope The scope of our assessment included manufacturing and warehousing workplaces and two wearables of interest for deployment in those workplaces to address musculoskeletal injuriesnamely,exoskeletons and ergonomic sensors.We assessed the status of the field of wearables as a whole,but we did not assess any particular brand of specific exoskeletons or ergonomic sensors.Methodology Literature search and review For all objectives,we reviewed relevant literature identified by agency officials,stakeholders,and a literature search conducted by a GAO research librarian.The librarian searched a variety of databases,including ProQuest and SCOPUS.We narrowed our search to articles published from 2019 through February 2024 to capture recent developments and uses of wearables as well as any quantitative metrics available on the effect of wearables on worker safety.Results of these searches could include scholarly or peer-reviewed material;government reports;trade or industry papers;and association,nonprofit,and think tank publications.The team used a two-tiered process to select the articles from the literature search that were most relevant to our objectives for further review.After review by two team members,the team identified and requested full texts of 24 studies which focused on in-scope technology(i.e.,exoskeletons and ergonomic sensors),and either 1)were validation studies measuring the performance of the technology,such as accuracy,in the lab or field or 2)were verification studies measuring the impact of the technology on worker safety in the lab or field.Two team members then reviewed the full text of the resulting studies to determine relevance.A Wearable Technologies GAO-25-107213 22 study was deemed relevant if it dealt with manufacturing,warehousing,or construction industries and focused on quantitative measures on the effect of the technology on worker safety.27 Eight of the 24 studies were determined to be relevant to field studies using these criteria.Additionally,the team completed a higher-level analysis for eight published studies on laboratory-based exoskeleton research identified from the literature search results.These studies did not meet criteria of having quantitative metrics on safety but did provide details on the laboratory work for determining muscle strain reduction from exoskeletons.Interviews and site visits We interviewed a selection of key stakeholders with experience and perspectives on the above objectives.We identified these stakeholders from a variety of sources including our review of literature,interviews,and prior GAO work:Officials from the Departments of Health and Human Services(National Institute for Occupational Safety and Health),Labor(Occupational Safety and Health Administration and Bureau of Labor Statistics),and Defense(Naval Sea Systems Command)Academic researchers Representatives from wearables manufacturing companies 27While construction was not in scope for this work,some studies for construction field work were included if there was substantive information about ergonomic sensors or Representatives from companies deploying,or who have deployed,wearables Representatives from worker organizations,including unions Representatives from a nonprofit organization focused on workplace safety,funded in part by industry donors Because this is a purposeful selection of the stakeholders involved in developing and using wearables,the results of our interviews are illustrative and represent important perspectives but are not generalizable.We also went on two site visits to companies deploying wearables who agreed to host our team,and we attended the Applied Ergonomics Society 2024 conference.During the site visits,we spoke to occupational health and safety professionals responsible for overseeing the deployment procedures and use of the wearables and to workers who are currently volunteering to use wearables or have used wearables in the past.During one site visit,we were also able to observe how workers used exoskeletons during their day-to-day work tasks.At the conference,we heard presentations from occupational health and safety professionals and academics,interfaced with several wearables manufacturers,and tried on some wearables.Ongoing activities After careful consideration of documentary and testimonial evidence,we determined that it would not be useful to identify policy exoskeletons and if the conclusions were applicable beyond the construction sector.Wearable Technologies GAO-25-107213 23 options because current activities,if continued,may address the challenges we identified.We therefore describe several ongoing activities for each relevant stakeholder group to consider continuing in lieu of providing policy options.The discussion of ongoing activities is neither a recommendation to federal agencies nor a matter for congressional consideration.We conducted our work from January 2024 through December 2024 in accordance with all sections of GAOs Quality Assurance Framework that are relevant to technology assessments.The framework requires that we plan and perform the engagement to obtain sufficient and appropriate evidence to meet our stated objectives and to discuss any limitations to our work.We believe that the information and data obtained,and the analysis conducted,provide a reasonable basis for any findings and conclusions in this product.Wearable Technologies GAO-25-107213 24 Appendix II:GAO Contact and Staff Acknowledgments GAO contact Karen L.Howard,PhD,Director,Science,Technology Assessment,and Analytics(STAA),at(202)512-6888 or HowardKgao.gov Staff acknowledgments In addition to the contact named above,the following STAA staff made key contributions to this report:Laura Holliday,MS,Assistant Director William K.Bauder,PhD,Analyst-in-Charge and Senior Physical Scientist Paulina Rowe,Analyst Kristen E.Watts,PhD,Senior Physical Scientist These staff also contributed to this work:Blake Ainsworth,Assistant Director Joshua Brownstein,PhD,Senior Economist Jenny Chanley,PhD,Senior Design Methodologist Jehan Chase,JD,Senior Attorney Nancy Cosentino,Senior Analyst Thomas Costa,Director Mary Crenshaw,Assistant Director Caitlin Dardenne,PhD,Senior Analyst Hedieh Fusfield,Senior Analyst Ryan Han,Lead Visual Communications Analyst Michael Holland,Assistant Director Mark Kuykendall,Senior Communications Analyst Umesh Thakkar,PhD,Senior Analyst Nihar Vora,JD,Assistant General Counsel Rachel Wexler,MPP,Senior Analyst GAOs Mission The Government Accountability Office,the audit,evaluation,and investigative arm of Congress,exists to support Congress in meeting its constitutional responsibilities and to help improve the performance and 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A subsidiary of the InternationalSociety of AutomationA subsidiary of the InternationalSociety of AutomationJULY 2024 Volume 3 Technology Trends that Empower Innovation Real-time Digital Manufacturing:Realized Open Automation Systems:An Update Insider Insights from Technology Suppliers9th Annual9th Annual Industrial Automation&Industrial Automation&Control Trends ReportControl Trends ReportVisit to learn more.TRUSTED BYWhen we named our industrial application software“Ignition”fifteen years ago,we had no idea just how fitting the name would become.One Platform,Unlimited PossibilitiesDIGITAL TRANSFORMATIONWith plant-floor-proven operational technology,the ability to build a unified namespace,and the power to run on-prem,in the cloud,or both,Ignition is the platform for unlimited digital transformation.Ignitions industry-leading technology,unlimited licensing model,and army of certified integration partners have ignited a SCADA revolution that has many of the worlds biggest industrial 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manufacturing,IIoT,cybersecurity,connectivity,machine and process control and more for industrial automation,process control and instrumentation professionals.To subscribe to ebooks and newsletters,visit: 2024 is published five times per year(March,May,July,September,and November)by A,a subsidiary of International Society of Automation(ISA).To advertise,visit: Society of AutomationSetting the Standard for Automationgroups/68581automationdotcomautomation_comcompany/internationalsocietyofautomationInternationalSocietyOfAutomationISA_InterchangeTrademarks used in this document are the property of their respective owners.Renee Bassett,Chief Editor Chris Nelson,Advertising Sales Rep Richard T.Simpson,Advertising Sales Rep Gina DiFrancesco,Advertising Sales Rep GDiF JULY 2024 AUTOMATION TRENDS REPORT 3IntroductionAUTOMATION 2024 VOLUME 39th Annual Industrial Automation&Control Trends ReportThe automation industry moves at warp speed and staying on top of news and trends is what A does for 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Beckhoff control system (TwinCAT,IEC 61131,Motion,Measurement,Machine Learning,Vision,Communication,HMI)Flexibly change paths in software and easily modify shape,size,and number of subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 7 Table of ContentsAUTOMATION 2024 VOLUME 3 AUTOMATION TRENDS REPORT3 Introduction4 Sponsors Index FEATURES39 Automation Is Essential for Manufacturing Growth By Bill Lydon,AWhy consider macroeconomic or wide-ranging technological trends?Because industrial growth and resilience depend on it.44 Real-time Digital Manufacturing:Realized By Bill Lydon,AApplying digital transformation techniques and new system design approaches make integrated,sensor-to-enterprise systems possible.51 Open Automation Systems Update on the State of the Art By Andre Babineau,John Conway,David DeBari,Alex Eaton,Kelly Li,Sarat Molakaseema and Josh SwansonExperts from UniversalAutomation.org,ExxonMobil,and other industry groups tell how modern software techniques are improving process automation systems.68 Technology Trends that Empower Innovation By Bill Lydon,AAdvances in 18 technology areas are empowering and inspiring manufacturers.Table of ContentsA subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 9 AUTOMATION 2024 VOLUME 3 AUTOMATION TRENDS REPORT15 AIs Role in Hyperautomation and Cybersecurity By Felipe Costa,MOXA Americas18 Web-based SCADA/HMI Clients Support Remote Services By Paul Shu,ARISTA Corporation 21 The Transformation of Robotics&Motion Control By Drew Thompson,Sealevel Systems24 OEM Hacks for Mitigating Labor Shortages and Lowering Costs By Mitsubishi Electric Automation,Inc.27 Ultra-long-life Lithium Batteries Make Smart Devices Smarter By Guy Peleg,Tadiran Batteries30 Modern Edge Devices Bring Harmony to Disjointed Protocols By Dan White,Opto 2233 Hardware for the Demands of AI-Powered Machine Vision By Axiomtek36 Securing Cloud Connections for Industrial AI Engines 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INDUSTRIAL DRIVE AUTOMATION ENGINEERING SERVICESCAN TO LEARN MOREthe#1 value in automationOrder Today,Ships Fast!*See our Web site for details and restrictions.Copyright 2024 AutomationDirect,Cumming,GA USA.All rights reserved.1-800-633-0405Whether you are a machine builder,systems integrator,or anyone looking for an advanced,low-cost controlssolution,the Productivity family of controllers has whatyou need.Built to go above and beyond,these controllers offer multiple networking solutions and easy device integration,plus some impressive“WOW!”factors like analog data and CPU status displays.On top of that,the Productivity PLC line also offers:CPUs with expansive 50MB memory Unmatched built-in communications capabilities,includinglocal and remote I/O ports,EtherNet/IP,MQTTS,custom protocols,and more Modular rack-based or stackable footprint with many discreteand analog I/O option modules,scalable up to 59K I/O FREE advanced tag name programming environment with a convenient project 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1Conference sessions on hot topics give you valuable,in-depth insights and knowledge to empower your journey in the automation industry.The expo brings you face-to-face with vendors from the industrial automation,process control and operational technology(OT)cybersecurity fields.Industry-leading ISA certificate training courses covering the ISA/IEC 62443 industrial cybersecurity standards will be offered in conjuction with the event.The ISA Honors and Awards Gala red carpet walk revs up the excitement aboard the USS Yorktown as we recognize the best of ISA.International Society of AutomationSetting the Standard for Automation30 September-3 October|Charleston,South Carolina,USRegister NowBecome a Sponsorase.isa.orgThe Automation Event of the Year!Visit ase.isa.org for a full list of activities and programs included in and held in conjunction with this event.Cybersecurity TrackSupply Chain Security,Protection Against Ransomware Attacks,and Safety and Integrity of Automated SystemsDigital Transformation TrackGenerative AI,Smart Manufacturing,Cloud Technology and Digital TwinsCareer Skills TrackLeadership Skills and Professional Development Within the Automation IndustryInsider InsightsAutomation trends from technology providers helping to empower manufacturers and shape the future of industry.AUTOMATION 2024 VOLUME 3 JULY 2024 AUTOMATION TRENDS REPORT 14 JULY 2024 AUTOMATION TRENDS REPORT 15 INSIDER INSIGHTAUTOMATION 2024 VOLUME 3standards facilitate interoperability and seamless integration of different systems and devices,essential for creating a cohesive and efficient industrial environment.However,the angle I would like to delve into is within cybersecurity.Historically,industrial and corporate applications have heavily depended on definitions and designs from large technology organizations,making it challenging to understand what security truly means and how it relates to systems.This challenge is even more pronounced in industrial applications(ICS),where security knowledge has only recently started to develop compared to corporate environments.Its crucial to recognize that the successful deployment of AI in industrial Undeniably,many of the trends discussed in the AUTOMATION 2022 Industrial Automation&Control Trends Report are more than trends now;they are moving to the“adoption”phase.Two of the trends gaining traction and paving the way for solid solutions to address current challenges are hyperautomation and the rise of open industrial standards.Now I will explore these two with a focus on cybersecurity.As a cybersecurity and AI researcher and industrial professional,Ive observed firsthand how these trends have evolved,particularly in integrating AI to enhance industrial operations and security,playing a critical role in todays industrial challenges.The first trend highlighted by Bill Lydon in 2022 that I will address is the rise of hyperautomation.This concept,involving the use of advanced technologies like artificial intelligence(AI)and machine learning(ML)to automate processes,has significantly matured.Hyperautomation is now a crucial driver for industries seeking to enhance productivity and efficiency.AI-driven tools are increasingly used to streamline operations,reduce human error,optimize resource management,and support cyber threat detection and responseAnother trend gaining traction is the adoption of open industrial standards.These AIs Role in Hyperautomation and CybersecurityThe IEC 62443 standard provides a robust framework for securing industrial control systems.Combined with AIs capabilities,it offers a powerful defense against cyber threats.By Felipe Costa,MOXA Americas JULY 2024 AUTOMATION TRENDS REPORT 16 AUTOMATION 2024 VOLUME 3INSIDER INSIGHTsettings requires a deep understanding of both technology and the industrial context.Many industries have unique operational constraints and regulatory requirements that must be addressed.For example,while AI can significantly enhance security measures,its implementation must consider the specific operational technologies(OT)in use,which often differ from traditional IT systems.This is where the IEC 62443 standard,in association with AI,plays a perfect match.Now,correlating these two parallel worlds,cybersecurity is a long journey with many priorities(although in theory,we can only have one priority;this word derives from the Latin“prioritas”meaning“what comes first”).The integration of AI has become indispensable,helping to manage these other“priorities”efficiently.My perspective as a cybersecurity expert aligns with the need for a comprehensive approach that incorporates industrial knowledge.The IEC 62443 standard provides a robust framework for securing industrial control systems.When combined with AIs capabilities,it offers a powerful defense against cyber threats.This synergy between AI and industrial cybersecurity not only improves threat detection and response but also enhances overall system resilience.The IEC 62443 standard emphasizes the importance of understanding the specific needs and constraints of industrial environments,preparing the ground for educated decisions,and most importantly,tangibly defining what security is and how to measure it.AI technologies can analyze vast amounts of data to identify patterns indicative of cyber-attacks,thereby enabling proactive threat mitigation.The priority of the company,defined by IEC 62443,is managing risks,and understanding where the most critical assets are to be protected.AI assists with“other priorities,”helping asset owners make informed decisions based on data,responding to threats,and improving performance by leveraging AI.In conclusion,the identified trends have materialized and are shaping the future of industrial automation and cybersecurity.However,further attention should be given to this topic now more than ever.Selecting industrial automation partners with the right expertise is fundamental.Historically,companies have risked using solutions from immature companies,which can do a disservice to technology.Poor results and even worse,incidents,could lead many to judge that the technology was not ready when,in fact,it was mistakenly deployed due to a lack of expertise.Felipe Costa is senior product marketing manager for networking and cybersecurity for MOXA Americas.He is a seasoned cybersecurity director and industrial cybersecurity instructor certified by ISA and EC-Council.Costa holds more than 30 certifications and has about 20 years of experience in the industrial sector.He has presented and published articles globally,including at the NASA Artificial Intelligence Congress.RKP SeriesRackmountComputing PlatformDRP SeriesDIN-Rail Computing PlatformBXP SeriesBox ComputingPlatformImprove Security and ManageabilityConsolidate Workloads and Reduce TCORapid and Cost-effective DeploymentGET IN TOUCH 1-888-MOXA-USA 1-714-528-Modernize YourAutomation SystemsMoxas new lineup of industrial PCs with advanced x86 architecture delivers a higher level of connectivity,intelligence,and performance for automation.Build a solution fit for any scenario with a comprehensive range of options.SCAN OR CLICKTO LEARN MORE JULY 2024 AUTOMATION TRENDS REPORT 18 INSIDER INSIGHTAUTOMATION 2024 VOLUME 3and be able to withstand cleaning solutions.ARISTAs AMW mobile workstations are constructed with 316L stainless steel materials,specifically for pharmaceutical manufacturing clean rooms.Generally,316 Modern manufacturing complexity requires automation systems to boost productivity and efficiency.The technologies most widely deployed on the plant floorremote desktop services and web-based SCADA/HMIare at the top of the list for delivering these benefits.The hardware on the production floor is as important as the SCADA/HMI software,and thin clients can deliver important benefits:Easy installation.A thin client tailored to run remote desktop services and support web-based HMI/SCADA can be deployed across the production floors with minimal installation efforts.Low maintenance.The SCADA/HMI software residing on the server,the thin client,and the web client is operating-system-independent.Its replacement can be quick and easy,and no software installation is required if any failure occurs to the thin client or web client.Industrial thin client/web client computers must meet environmental protection requirements for every stage of the manufacturing process and in every industry sector.The industrial thin client computers in the pharmaceutical industrial sector,for example,must meet IP66 environmental protection standards Web-based SCADA/HMI Clients Support Remote ServicesFor improving processes and allowing resources to be more productive,a thin client in a manufacturing environment is an ideal platform to deliver versatile benefits.By Paul Shu,ARISTAArista Industrial Q8 Edge web clients and thin clients provide many flexibility and management benefits.JULY 2024 AUTOMATION TRENDS REPORT 19 AUTOMATION 2024 VOLUME 3INSIDER INSIGHTsteel is specified for environments with strict cleanliness requirements,or when equipment is exposed to harsh chemical cleaners and corrosive environments that 304 stainless steels cannot withstand.316L offers increased protection against salt,proteins,and strong acids or bases.It also possesses enhanced resistance to chlorides and chlorinated solutions that are common in controlled environments and cleanrooms.A thin client/web client could also be designed for use in hazardous environments where the existence of flammable gases or vapors and/or combustible dust may be present in the air or become present during a spill or leak.A thin client/web client designed for Class 1 Division 2 hazardous zone applications helps prevent the ignition of flammable substances like gases,vapors,and liquids.ARISTAs ARP-2200AP series,for example,includes the panel-mounted thin client/web client products family.ARP-5500AX Series and ARP-3821AX are stainless steel,fully sealed,and fully enclosed thin and web clients and have no external vents.In this way,they protect the components from gases,dust,dirt,moisture,chemicals,oil,and other external contaminants in an explosive environment.For improving processes and allowing resources to be more productive,a thin client in a manufacturing environment is an ideal platform to deliver versatile benefits.Manufacturing operations at times get stuck due to necessary IT setup time.This often leads to downtime and waste of resources.Thin client technology is developed to resolve such conflicts and provide a mature approach for processes to be conducted efficiently.More thin client advantages include:Lower operational cost.Thin clients eliminate the stress of setting up a full-fledged workstation.Since all the computing is done on servers,machines do not require much energy to operate.This contributes to an overall cost reduction.Centralized management.With a thin client set-up,only software-level protection is required.Security is required on the server level since all the data is stored on it.Additional heavy-duty security is not required for workstations and other devices.This significantly reduces the effort and time required in setting up workstations and working with every single machine in case of downtime.High performance.thin clients can be integrated into almost every industry.Areas such as manufacturing,healthcare,or finance that need utmost accuracy can rely on the thin client without any second thoughts.Paul Shu is President of ARISTA Corp.,a leading provider of computing platforms and visualization display products for pharmaceutical manufacturing environments.He has worked in the industrial automation industry for over 20 years and is skilled in business development,cloud computing,visualization,sales management and computer repair.Shu has a Bachelor of Science(B.S.)with a concentration in Electronics Engineering.JULY 2024 AUTOMATION TRENDS REPORT 21 INSIDER INSIGHTAUTOMATION 2024 VOLUME 3Essentially,AI and ML enable robots and other autonomous machines to learn from data,adapt to new situations,and improve their performance over time.Broadly,actuators allow robots and autonomous machines to act upon,or react,to the data gathered from the various sensor systems.Advances in actuators from electric,hydraulic,and pneumatic systems have led to more precise,powerful,and efficient motion control.Edge computing and Internet of Things(IoT)technology enable real-time data processing and decision-making at the robot or individual machine level,reducing latency and improving efficiency in robotic systems.Advances have transformed both the robotics and motion control industries and the costs associated with deploying these innovations have been reduced dramatically.As a result,robotics technology and motion control systems are being deployed across various applications.Traditional technologies,like sensors and actuators,are being used alongside AI,machine learning,and edge computing to bring robotics and motion control to life.For example:Sensor systems are the primary means through which robots and other autonomous machines gather information about their environments to work safely and effectively.Vision systems can be thought of as very specialized sensors.Essentially,vision systems allow robots and autonomous machines to capture,process,and interpret visual information from the world around them to make decisions.This is crucial for performing tasks like navigation,inspection,and manipulation.Advances in artificial intelligence(AI)and machine learning(ML)are among the most important factors driving robotics and motion control systems.The Transformation of Robotics&Motion ControlSensor systems,vision systems,AI and machine learning,advanced actuators,and edge computing are the core technologies propelling these innovations forward.By Drew Thompson,Sealevel Systems JULY 2024 AUTOMATION TRENDS REPORT 22 AUTOMATION 2024 VOLUME 3INSIDER INSIGHTManufacturing,automated vehicles and moreRobots and robotic arms have been adopted as control systems and have made it possible for them to carry out precision assembly tasks that require pinpoint accuracy.Vision systems have dramatically improved the speed of quality control and product inspections by allowing automation of many of the tasks.AI and ML have led to a greater understanding of processes and to better resource allocation,energy efficiency,and overall process optimization.Robotics and motion control systems are driving substantial improvements in autonomous vehicle(AV)functionality,safety,and efficiency.The perception and sensing functionality of AVs has grown by leaps and bounds in the last few years,both in terms of accuracy and in the ability to react.Another area of rapid AV improvement is the motion planning and control functionality.The robotic and motion control hardware inside AVs is now able to compute the safest and most efficient path for the vehicle,all while considering factors like road conditions,traffic,and obstacle avoidance.Many of the same advances in consumer-grade AVs apply to military and aerospace vehicles like unmanned aerial vehicles(UAVs)and unmanned ground vehicles(UGVs),as well as seagoing drones,called unmanned surface vehicles(USVs)or autonomous underwater vehicles(AUVs).In addition to the various vehicle-type drones,there is a whole class of autonomous combat robots currently in use or active development through such programs as the Modular Advanced Armed Robotic System(MAARS)or Special Weapons Observation Reconnaissance Detection System(SWORDS).There has also been a recent push to automate segments of military logistics through the use of autonomous trucks and UGVs.Specifically,to transport supplies and equipment in contested or dangerous areas,reducing the risk to human drivers and ensuring reliable logistics.The future of roboticsThe rapid advances in robotics and motion control systems have significantly transformed various industries by driving down costs and enhancing performance across multiple applications.Sensor systems,vision systems,AI and machine learning,advanced actuators,and edge computing are the core technologies propelling these innovations forward.As robotics and motion control systems continue to evolve,their impact will undoubtedly expand,further integrating these technologies into everyday operations.Drew Thompson is a technical writer and marketing specialist for Sealevel Systems,the leading designer and manufacturer of embedded computers,industrial I/O,and software for critical communications.A writer/editor by training,Thompson spends his days creating and delivering content relevant to Sealevels technical community and business partners.SEA-24008 Sealevel Flexio Print Full Page Ad B24.pdf 1 3/11/24 11:49AM JULY 2024 AUTOMATION TRENDS REPORT 24 INSIDER INSIGHTAUTOMATION 2024 VOLUME 3 A single programming environment for every phase of developmentfrom design,to programming,debugging,and maintenance Advanced diagnostics for quickly identifying,communicating,and resolving issues even before team members arrive at the machine Advanced simulators that not only let you simulate the PLC logic but also the HMI and 3D digital twinsWith the right software,you can address challenges across the lifecycle of the component.When the right software is usedduring the design stage and through startup,the operating stage,and during Its common knowledge that lifecycle management for machines can save time,effort,and resources.It can also increase reliability,decrease unplanned downtime,and extend the life of machines.The same is true for automation components including PLCs,robots,and HMIs.Lifecycle management at the component level?Yeah,thats a thing.Global disruptions,such as nationwide labor shortages,loss of experienced personnel,and margin pressures,are driving the adoption of lifecycle management down to the component level.Digital transformation technologies are increasing demand and creating capacity issues.Its all converging to the point where original equipment manufacturers(OEMs)need a better way forward.In other words,if an OEMs core competency is product innovation and design,and theyre hemorrhaging experienced engineers and cant find replacements,they need to rethink the way things are done.Having high-quality automation components is not enough.Advanced engineering software is now an essential ingredient for remaining competitive.When selecting engineering software,look for these essential attributes.OEM Hacks for Mitigating Labor Shortages and Lowering CostsComponent-level lifecycle management makes trouble-free engineering possible.It can improve every phase of development and help deliver high-quality,low-maintenance machines at scale.By Mitsubishi Electric Automation,Inc.JULY 2024 AUTOMATION TRENDS REPORT 25 AUTOMATION 2024 VOLUME 3INSIDER INSIGHToptimizationyou can accelerate time-to-market,reduce commissioning time,cut downtime and maintenance costs,and optimize runtime and overall equipment effectiveness(OEE).The design stage is all about reducing time-to-market.For the design stage,look for these time-savers:intuitive drag-and-drop functionality,custom function blocks&libraries,advanced simulation,and a modern HMI.The startup stage is all about reducing time to commission.One way to reduce commissioning time is to create easy access to the data needed to fine-tune your machine to the applications needs.Web pages and other user interface tools give you access to the information needed to make adjustments.They can also tell you how those adjustments have affected your process.For the startup stage,look for a system recorder module,HMI and VFD/Servo templates,PLC and HMI web server visualization,custom web pages and interfaces,and support for multiple languages.During the operating stage,reducing downtime is key.All machines will go down at some point.Your software should have advanced diagnostic tools that help you quickly identify,communicate,and offer resolutions to team members before they even arrive at the machine.An important capability in this stage is event recorder modules that fully record and sync up the program state changes(electrical)and a camera(mechanical)for a set amount of time before and after an event takes place.An event recorder module uses the PLC program,HMI software,and a camera to observe the events leading up to an error.Other key capabilities to look for include predictive maintenance,HMI backup and restore,enterprise system integration,and HMI mobile and reporting capabilities.The final stage,optimization,is all about having actionable data to drive intelligent business decisions.For this stage,look for advanced process optimization and advanced data collection,reporting,and analysis.Since optimization is a cyclical process,there is always room for improvement.Component-level lifecycle management makes trouble-free engineering possible.It can improve every phase of development and help you deliver high-quality,low-maintenance machines at scale.It can also help you mitigate risk in the technology lifecycle,extend your machines period of profitability,lower service costs with predictive maintenance,and increase customer loyalty.As one of many Mitsubishi Electric automation affiliates around the world,Mitsubishi Electric Automation,Inc.,is part of a$40 billion global company serving a wide variety of industrial markets with a family of automation products including programmable logic controllers,variable frequency drives,operator interfaces,motion control systems,computer numerical controls,industrial robots,and servo amplifiers and motors.AD-VH-00171us.MitsubishiE Mitsubishi Electric Automation,Inc.JULY 2024 AUTOMATION TRENDS REPORT 27 INSIDER INSIGHTAUTOMATION 2024 VOLUME 3range,typically powered by primary(non-rechargeable)batteries.Certain niche applications draw higher amounts of average current measurable in milli-Amps with pulses in the multi-Amp range,typically powered by an energy harvesting device in combination with a lithium-ion(Li-ion)rechargeable battery to store the harvested energy.The batterys self-discharge rate is a critical consideration,as chemical reactions draw current from a cell even when it is disconnected or in storage.The self-discharge rate can vary based on numerous factors,most importantly the passivation effect.Passivation involves a thin film of lithium chloride(LiCl)that forms around the anode of an inactive LiSOCl2 battery to limit its reactivity.Whenever a continuous Low-power smart devices are being deployed worldwide to support applications ranging from SCADA to remote sensing,tank-level,flow and environmental monitoring,predictive maintenance programs,and more.Applications that involve long-term deployments are predominantly powered by ultra-long-life primary(non-rechargeable)bobbin-type lithium thionyl chloride(LiSOCl2)batteries,which are preferred for their exceptionally high capacity and energy density,wide temperature range,incredibly low self-discharge rate,and superior performance in harsh environments.For example,Wavelet devices from Ayyeka use bobbin-type LiSOCl2 batteries to power intelligent,AI-enhanced solutions that monitor hard infrastructure such as pipelines,control valves,flowmeters,tank levels,and more.These devices are modular,scalable,flexible,autonomous,sensor-agnostic,military-grade TLS v1.3 encrypted,and plug-and-play with no major coding skills required.Ultra-long-life bobbin-type LiSOCl2 batteries deliver a reliable power supply without requiring access to the AC power grid.Passivation:key to extended lifeMost low-power devices,including Wavelet,draw average current measurable in micro-Amps with pulses in the multi-Amp Ultra-long-life Lithium Batteries Make Smart Devices Smarter Standard bobbin-type LiSOCl2 cells are uniquely capable of harnessing the passivation effect,but they cannot generate high pulses due to their low-rate design.A hybrid solution is best.By Guy Peleg,Tadiran Batteries JULY 2024 AUTOMATION TRENDS REPORT 28 AUTOMATION 2024 VOLUME 3INSIDER INSIGHTload is applied,the passivation layer initially causes high resistance and a temporary drop in voltage until the discharge reaction begins to dissipate the LiCl layer:a process that repeats during prolonged periods of inactivity.The level of passivation fluctuates based on variables such as how the cell is manufactured,the quality of the raw materials,current capacity,length of time in storage,storage and discharge temperature,and prior discharge conditions,such as removing the load from a partially discharged cell increases the level of passivation,especially as the battery ages.All batteries are not created equalStandard bobbin-type LiSOCl2 cells are uniquely capable of harnessing the passivation effect,but they cannot generate high pulses due to their low-rate design.A hybrid solution is to combine a standard bobbin-type LiSOCl2 cell that delivers low-level background current during standby mode with a patented hybrid layer capacitor(HLC)that delivers high pulses during active mode,often to power bi-directional communications.The HLC features a unique end-of-life voltage plateau that can be interpreted to deliver low battery status alerts.Significant differences exist between the highest quality bobbin-type LiSOCl2 cells with a self-discharge rate as low as 0.7%per year(able to last up to 40 years)versus inferior quality cells with a self-discharge rate of up to 3%per year.Unfortunately,it can take years for such quality differences to become fully measurable.As a result,due diligence is required when evaluating competing brands,thus requiring well-documented long-term test results along with real-life performance data from the field involving comparable devices operating under similar loads and environmental conditions.End-user testimonials are also extremely valuable.A real-life exampleNationwide,the American Society of Civil Engineers(ASCE)estimates that 6 billion gallons of potable water are lost each day due to leaking pipes.Erie County,Pennsylvanie utilizes pressure-reducing valves to prevent leaking pipes and burst water mains across a 100-year-old system stretching 600 miles and serving over one million people.Wavelet devices are combined with Ayyekas Field Asset Intelligence software to deliver a comprehensive solution that continuously monitors pressure levels to identify potential ruptures and issue alerts via automated text messages,emails,or cell phones.Ultra-long-life bobbin-type LiSOCl2 batteries extend operating life to reduce long-term maintenance costs.Guy Peleg is vice president of marketing,sales,and business development for Tadiran Batteries.Based out of Lake Success,NY,USA,Tadiran manufactures a variety of industrial grade lithium batteries that offer unrivaled performance,including 40-year bobbin-type LiSOCl2,TLM Series high power,and TLI Series 20-year rechargeable Li-ion cells.Tadiran Batteries2001 Marcus Ave.Suite 125ELake Success,NY 110421-800-537-1368516-621-If you have a smart automatic water,gas,electricity,or heat meter in your home.If you have an electronic toll collection transponder,tire inflation sensor,or emergency E-CALL system in your car.If you have a GPS tracking device on your trailer,container,or cargo.If you have wireless sensors,controls,or monitors in your factories and plants.If you use electronics with real-time clock for memory back-up in your office.If you have never heard of Tadiran Batteries,it is only because you have never had a problem with our products powering your products.Take no chances.Take Tadiran batteries that last a lifetime.*Tadiran LiSOCl2 batteries feature the lowest annual self-discharge rate of any competitive battery,less than 1%per year,enabling these batteries to operate over 40 years depending on device operating usage.However,this is not an expressed or implied warranty,as each application differs in terms of annual energy consumption and/or operating environment.You probably already use Tadiran batteries,but just dont know it!PROVEN40YEAROPERATINGLIFE*JULY 2024 AUTOMATION TRENDS REPORT 30 INSIDER INSIGHTAUTOMATION 2024 VOLUME 3systems to fail or spend a ton ripping and replacing your controls to support the latest protocols?Thanks to modern edge devicescomputing systems that process data locally at the sourceyou dont have to make that choice.Thankfully,the latest edge devices include serial ports and software tools for RS-232,RS-485,and CAN Buseverything from simple USB-to-serial interfaces through dedicated,configurable,multi-channel I/O modules.You can achieve bidirectional serial communication in open programming platforms like Node-RED,JavaScript,Python,C ,and more.Or,if you prefer ladder diagrams and function blocks,use an IEC If TCP/IP won the“protocol wars”in the 90s,why are you still fighting protocol battles on the plant floor today?Because industrial networks were around long before the Internet.As far back as the 1960s,machines communicated via serial networks like RS-232,RS-485,and CAN buswith specialized proprietary fieldbus protocols like Modbus,Profibus,and DeviceNet.Even with TCP/IP on Ethernet,specialized protocols remainedModbus now has a TCP/IP version,Profibus gave way to ProfiNET,DeviceNet to EtherNet/IPeven some new ones joined the protocol party.After the industry demanded interoperability,OPC was born.Now we have OPC UA,a big step toward a unified architecture on OT networks.Meanwhile on the IT side,using HTTP and HTTPS was common.Its how web browsersand most of the internetworks today.MQTT Sparkplug came later.It is built on efficient,secure,and scalable publish/subscribe communications.This makes it a great fit for digital transformation projects and the industrial internet of things(IIoT).You want to digitally transform,but your existing machines dont support all these protocols.So,should you put off digital transformation while waiting for existing Modern Edge Devices Bring Harmony to Disjointed ProtocolsWithout disturbing existing systems,edge devices make it easy to convert data from a custom fieldbus into open protocols for digital transformation.By Dan White,Opto 22 JULY 2024 AUTOMATION TRENDS REPORT 31 AUTOMATION 2024 VOLUME 3INSIDER INSIGHT61131-3 compliant PLC programming platform.Alternatively,PLCs sold today all run Ethernet-based fieldbuses.Theyre suited for coordinated motion-control applications where low latency and precise synchronization are paramount,but they may not fit for digital transformation.Thankfully,you dont have to rip out and replace your PLCs.Edge devices today have SCADA tools and programming platforms with native drivers for all the most popular protocols.Without disturbing existing systems,edge devices make it easy to convert data from a custom fieldbus into open protocols for digital transformation.One of those open protocols is OPC-UA,which creates interoperability among PLC and I/O platforms.Youll find options for both client and server functionality on the latest edge devices.Native OPC UA servers expose I/O values from physical modules.SCADA-supported OPC UA servers provide southbound connectivity to fieldbuses and northbound connectivity to HMI dashboards and historians.And both clients and servers in IEC 61131-3 compliant PLC programming platforms provide endless interconnectivity options.REST API and MQTT SparkplugREST application programming interfaces(APIs)are a common way to pass information across IT infrastructure.These APIs are a standard way to use HTTP or HTTPS messages to send and receive data in common formats like XML or JSON.IT and programming professionals use tools like Swagger to understand,test,and integrate with someone elses API by exploring documentation,trying out endpoints,and generating client code for seamless integration.And yes,modern edge devices support this technology as well.As for MQTT Sparkplug,this technology for IIoT communications employs a publish/subscribe architecture.Originally designed for an industrial SCADA application,MQTT Sparkplug should be at the heart of any digital transformation project.With MQTTs Unified Namespace(UNS),you can model your data with context and create a plug-and-play architecture for all your machines.Your edge device gives you a single source of truth for your data(where it originates)and then securely publishes your data where its needed.The result is you can use the latest in machine learning,artificial intelligence,advanced analytics,and anomaly detection.Daniel White has worked at Opto 22 for more than a decade.His Tufts Engineering background,MBA in International Business,and prior industrial controls experience give him a unique edge on automation.White enjoys staying active through biking,basketball,skiing,and keeping up with his three young kids.JULY 2024 AUTOMATION TRENDS REPORT 33 INSIDER INSIGHTAUTOMATION 2024 VOLUME 3powered systems with the processing power to analyze large quantities of data.To meet these demands,advanced AI machine vision capabilities require industrial computers with a variety of characteristics.High Processing power.Edge computers should have the flexibility to support a wide range of CPU and GPU requirements to meet a diverse range of future workloads.To help future-proof,systems should support the latest CPUs,such as,12th,13th,and 14th generation Intel Core processors.The latest DDR memory with high bandwidth is needed to support faster transfer of stored data for real-time analysis.Automation is progressing rapidly with Industry 4.0 initiatives aiming to improve quality,efficiency,and productivity across various industries,including manufacturing,food and beverage,logistics,healthcare,and more.For machine vision systems,that means enhanced data from industrial Internet of Things(IIoT)sensors and innovative high-resolution camera technology that can capture a wide range of information to help overcome issues related to real-world complexities.However,the most significant Industry 4.0 technology is artificial intelligence(AI),pushing the capabilities of machine vision systems to supercharge speed,efficiency,and accuracyMachine vision systems empowered by edge AI can quickly and easily analyze images in real-time to recognize subtle nuances and patterns,compare patterns across an entire data set of images,and retain information from each analysis to learn and improve accuracy over time continuously.With this in mind,integrating new technologies into existing manufacturing and assembly lines comes with challenges.System integrators must choose the right hardware that can support a wide range of complex components,diverse connectivity options,and the need to support current and future AI-Hardware for the Demands of AI-Powered Machine VisionMachine vision systems empowered by edge AI can quickly and easily analyze images in real time to recognize subtle nuances,compare patterns,and retain information to improve accuracy over time.By Axiomtek JULY 2024 AUTOMATION TRENDS REPORT 34 AUTOMATION 2024 VOLUME 3INSIDER INSIGHTComprehensive I/O support.A wide variety of interfaces for supporting the latest devices is a key feature to look for in a machine vision edge computer.Key features include chipsets with digital interfaces for high-speed industrial cameras and I/O support for audio systems,KVM devices,serial communications(RS232/422/485),displays,and external platforms.Secure high-throughput networking.Every edge computer should feature secure,high-bandwidth connections to both internal and external networks via multi-gigabit Ethernet LAN ports.They should support 5G wireless connectivity for the increasing number of industrial sensors and devices used in remote monitoring,mobile robots,autonomous vehicles,asset tracking,AR,VR,and digital twins.Intelligent PoE device management.Edge computers should ensure safe power supply to components through DC input power while providing intelligent power management,including managing and monitoring power consumption per port for remote power distribution technologies like USB and Power over Ethernet(PoE)for connected devices,including cameras,lights,and sensors.Scalability.As AI technology evolves,edge computers should offer flexible expansion options and optional modules with additional I/O ports.This allows for easily scaling systems to accommodate current and future machine vision technologies,extending the systems lifespan.Industry compliance and durability.Edge computers deployed near assembly lines must be robust and designed to withstand the harsh realities of industrial and manufacturing environments,including exposure to shock,vibration,extreme temperatures,humidity,electromagnetic interference,dust,and debris.For added assurance,any industrial edge hardware should comply with the latest performance and safety standards applicable to electronic equipment intended for use in industrial environments.This includes wide-operating temperature ranges,IEC/EN 61000-6-2 and 61000-6-4 EMC certifications,and IEC 60068-2-27 and 60068-2-64 certifications for shock and vibration resistance.Customization optionsSince each machine vision application and environment has unique requirements,off-the-shelf systems may not always meet specific needs.System integrators should consider edge computers backed by design and integration services to meet precise project specifications.These services can customize solutions to unique requirements.Axiomtek,a provider of industrial PCs,is committed to advancing machine vision applications and emerging AI technologies.Our U.S.-based design engineering and integration services,alongside our DigiHub of SDKs and development resources,empower system integrators to deploy edge machine vision systems for any application.JULY 2024 AUTOMATION TRENDS REPORT 36 INSIDER INSIGHTAUTOMATION 2024 VOLUME 3systems,they were conceived in the early 2000s,long before people were thinking of moving industrial data to the cloud.The OPC UA protocol by itself is simply too complex to reproduce well in a daisy chain across multiple servers.Information will be lost in the first hop.The synchronous multi-hop interactions needed to pass data across a DMZ would be fragile and result in high latencies.MQTT,on the other hand,can be daisy-chained but it requires each node in the chain to be individually configured and aware that it is part of the chain.The quality of service(QoS)guarantees in MQTT cannot propagate through the chain,making data at the ends of the chain unreliable.MQTT is thus best used as the last step only,to move data from the DMZ to the cloud.The future of industrial artificial intelligence(AI)looks bright.Initial studies and pilot projects point to significant efficiency gains and cost savings made possible by connecting production systems to AI engines.However,there is at least one serious challenge.How do we keep those production systems and their data completely secure?After all,most AI tools are cloud-based.Whats needed is a secure,real-time connection from the plant to the AI system running in the cloud.The recommended approach for industrial data security is complete network segmentation.The OT(operations)system should be fully isolated from the Internet and cloud systems.This is best done using a DMZ(demilitarized zone),keeping the production network behind closed firewalls.Governments and industry leaders worldwide agree on this basic industrial cybersecurity practice,and the NIS2 Directive and NIST CSF 2.0 require it.Protocol challengesGetting data from production to a cloud-based AI system through a DMZ requires two steps:plant-to-DMZ,and DMZ-to-cloud.However,OPC-UA and MQTT were not designed for this type of pathway.Although often used in Industrial IoT and Industry 4.0 Securing Cloud Connections for Industrial AI EnginesGetting data from production to a cloud-based AI system through a DMZ requires two steps:plant-to-DMZ,and DMZ-to-cloud.By Xavier Mesrobian,Skkynet JULY 2024 AUTOMATION TRENDS REPORT 37 AUTOMATION 2024 VOLUME 3INSIDER INSIGHTWhat about combining OPC UA and MQTT?Getting data securely from the plant to the DMZ is a challenge.Using OPC UA for that step has a serious pitfallas it requires opening a firewall on the production network.Any OPC UA client on the DMZ would need to connect through the firewall to the OPC UA server in the plant.Opening a firewall into the plant for this connection is too high a risk,and most security administrators will not allow it.Tunnel/mirror technologySince neither OPC-UA nor MQTT alone or together are sufficient for passing data through a DMZ,another approach is neededone that integrates well with both protocols.Secure tunnel/mirror software with a unified namespace provides a solution.It can make the connections at both ends and pass the data along the daisy-chained connections necessary for DMZ support.Tunneling or mirroring connections typically use two software components.The first component makes the necessary connections at the production level to collect data from various industry protocols into a single unified namespace.It then tunnels the data to the second component running on the DMZ.The second component converts the data to MQTT and sends it from the DMZ to the AI service in the cloud.The mirroring capability of the tunnel/mirror software keeps the data consistent between the original data source,the DMZ,and the AI system.As mentioned previously,all inbound firewall ports on the production system must be kept closed at all times.The tunnel/mirror system must be able to make outbound-only connections from the production network to the DMZ.In addition,some high-security,critical infrastructure applications require a hardware data diode to ensure that not a single data packet can be sent back from the DMZ to the industrial network.A tunnel/mirror system would need to support that level of secure architecture for those applications.Other AI implementations may call for bidirectional data flow to enable hands-off supervisory control or similar data inputs back into the production system.The tunnel/mirror technology should be flexible enough to support that if needed.In any case,there should be no access to data beyond what the AI system uses.Plant engineering staff should have full control over which data should be made available.Summing up,to optimize production systems many companies today are turning to industrial AI.The challenge they face is how to access the data they need without compromising security.This is difficult,but not impossible.Xavier Mesrobian is the vice president of sales and marketing at Skkynet,a global leader in industrial data connectivity.With 25 years in the industry,Skkynet software and services are used in over 27,000 installations in 86 countries including the top 10 automation providers worldwide.A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 39 AUTOMATION 2024 VOLUME 3Industrial automation has become increasingly essential for manufacturing companies to grow and prosper.Investments in industrial automation improve overall manufacturing business performance in many areas including:Consistent production quality Customer service,including product customization Reduced variable labor costAutomation is Essential for Manufacturing GrowthBy Bill LydonWhy consider macroeconomic or wide-ranging technological trends?Because industrial growth and resilience depend on it.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 40 Solved labor shortages and skills gaps Lower energy costs Lower production waste.Industrial automation and controls benefit from technology developed and proven for high-volume commercial and business applications that deliver high performance at lower cost.The evolution of industrial controls and automation has leveraged commercial and business technological developments when they become established and reliable.Past examples include expensive and cumbersome operator workstations custom-built by automation and distributed control system(DCS)suppliers that later gave way to commercial off-the-shelf(COTS)PCs and Microsoft Windows platforms,providing greater value at lower cost and industrial networks running over standard Ethernet.Automation professionals are becoming increasingly important to create value for their employers by keeping up to date with the latest automation technologies,techniques,and solutions to build superior applications.Automation professionals are important contributors to the competitiveness and overall success of manufacturing companies.The cumulative leverage of applying various new methods and products to improve manufacturing efficiency and quality is significant.Certainly,high visibility and much-hyped new technologies are exciting and important.Yet,the more subtle,seemingly small improvements understood by automation professionals are,over time,just as critical to building success.The best ideas and new trends dont arise in an intellectual vacuum.If you want to brainstorm innovations that go beyond solving problems and increasing productivity and performance,you must gather new ideas from multiple sources.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 41 Open natural progressionThe established industrial automation industry has experienced relatively few changes over the years,compared to other industries.Many of the major industrial automation innovations of the recent past,such as adopting Microsoft Windows,industrial Ethernet networks,and application virtualization were accomplished using COTS technology.The level of usability,flexibility,and multivendor interoperability in the business enterprise and information technology(IT)sector is significant.Open systems create ecosystems that leverage human and investment capital to create solutions.These ecosystems can create more value and innovation than any single company.Disruptive innovationsDisruptive innovations create new value so users can achieve better results and,in many cases,more functionality.These innovations may be new applications or may replace traditional methods and solutions.In addition,disruptive innovation can change organizational structure including roles and responsibilities that are not initially obvious.Amazon,Uber,iTunes,and Airbnb are well-known disruptive examples that are not directly related to industrial manufacturing and automation but do illustrate the creative application of technology and new concepts that have dramatically changed commerce.Industrial examples include the use of hydraulics to replace mechanical methods(i.e.,cable,pulley),digital systems to replace pneumatic proportional-integral-derivative(PID)controllers,and mechatronics to replace gearboxes and mechanical camming with programmable coordinated motion.The subtle part of disruptive innovation is that many times it is the combination and creative and innovative application of new off-the-shelf technology to build new and better solutions that result in significant improvements,ease of use,and added functions.“The Innovators Dilemma”by Clayton Christensen explains how successful A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 42 AUTOMATION 2024 VOLUME 3companies fail by sticking to their established business models,overlooking disruptive innovations while newer and/or less-established organizations often do otherwise.An example is Kodak,which was slow to fully embrace digital and instead continued to focus on its traditional film business.Competitive success factorManufacturing and process companies that do not take advantage of the appropriate disruptive innovations are likely to become uncompetitive at some point and be leapfrogged by their competitors.Conversely,companies that leverage disruptive innovations position themselves to become leaders in their industry.History provides numerous examples of companies using innovative thinking and technology to become industry leaders.Ford dominated the early automotive industry.More than 100 years ago,Henry Ford and his team at the Highland Park assembly plant launched the worlds first moving assembly line.It simplified the production of the Model Ts 3,000 parts by breaking production into 84 distinct steps performed by groups of workers as a rope pulled the vehicle chassis down the line.Andrew Carnegie built his steel-making business leveraging technology with new processes such as the Bessemer process.He installed new material-handling systems including overhead cranes and hoists to speed up the steel-making process and boost productivity.Carnegie was relentless in his efforts to drive down costs.He would tear out and replace equipment at his mills if better technology was developed to reduce costs and make his mills more efficient.Federal Express Corporation,founded in 1971,leveraged barcode and computer technology to achieve dramatic growth.One of FedExs great contributions was the tracking system launched in the 1970s,which has become standard in shipping.It was initially an internal process for quality control.When the system went online,it included early prototypes of handheld computers that scanned package barcodes with wands.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 43 Looking for insight and innovationYou might think creativity starts with a random idea,but the truth is that the best ideas and new trends dont arise in an intellectual vacuum.If you want to brainstorm innovations that go beyond solving problems and increasing productivity and performance,you must gather new ideas from multiple sources.We have been conditioned to believe the only way to get big results is to make a big change.This can sometimes be true,but these opportunities are typically expensive and rare.Many times,the little-change ideas can be as powerful as the big ones.Smaller changes have the advantage of being an additive,instead of an overhaul,and thus may be able to yield big results while being less costly,less risky,and less disruptive.Look to the insights of others and consider macroeconomic trends or technological advances from outside your industry.Thats where the little-change ideas for your operations can be found.ABOUT THE AUTHORBill Lydon is editor emeritus of A and InTech magazine,publications from the International Society of Automation.He has more than 25 years of experience designing and applying automation and control technology,including computer-based machine tool controls,software for chiller and boiler plant optimization,and a new-generation building automation system.Lydon was also a product manager for a multimillion-dollar controls and automation product line,and later cofounder and president of an industrial control software company.He now acts as an industrial automation business coach and consultant on manufacturing digitalization and other topics.A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 44 AUTOMATION 2024 VOLUME 3Worldwide manufacturing had a wake-up call with the pandemic and supply chain disruptions.Outsourcing for lower costs has created pain and is a pressure point with negative impacts both on sales and on increasing profitability risk.However,the foundations of manufacturing and production are being reshaped by the integration of manufacturing production into the entire industrial business system.A digital manufacturing architecture offers a streamlined approach to enterprise-wide clarity that allows stakeholders to adjust operations based on real-time insights,i.e.,data transparency.Worldwide industrial digitalizationThe impact of open manufacturing initiatives continues to advance worldwide as countries and industries recognize the need to modernize with Industry 4.0,and other related initiatives being adopted and Real-time Digital Manufacturing:REALIZEDBy Bill LydonApplying digital transformation techniques and new system design approaches make integrated,sensor-to-enterprise systems possible.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 45 accelerating.These provide models for all industrial manufacturing organizations to achieve holistic and adaptive open automation system architectures.Germanys Industry 4.0 initiative ignited worldwide cooperative efforts in other countries including China,Japan,Mexico,India,Italy,Portugal,and Indonesia to apply technology to increase production competitiveness.At the same time,the lack of investments by companies,governments,and schools in vocational and technical education is a major issue.In the decades after the Second World War,high school dropouts could walk onto factory floors all around America and find decent,secure,middle-class jobs;this is no longer the case.Companies for many years have not invested in meaningful internships and apprenticeships,further drying of the skilled labor pipeline.Certainly,unskilled labor continues to be eliminated by automation,but industry still requires skilled and knowledgeable people educated to work with new manufacturing technologies.These trends are being helped by the rise of real-time manufacturing business systems.Digital transformation is creating an integrated real-time system from sensor to enterprise and cloud,which is now possible with the application of open standards and technology.Manufacturing and production companies increasingly are digitalizing to overcome the inefficiencies of siloed systems that create overlaps in processes and,more importantly,gaps in knowledge that stifle collaboration,efficiency,and ultimately growth.Digital transformation is empowering companies to realize holistic manufacturing business.This is achieved with a real-time distributed manufacturing architecture(DMA).Achieving lean,high-velocity manufacturing requires product,material,and information flow all working in concert.Information flow Industry still requires skilled and knowledgeable people educated to work with new manufacturing technologies.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 46 impacts the efficiency of a responsive manufacturing supply chain.Intelligent manufacturing systems ensure optimized,fast,and reliable product and material flow.These systems should be integrated and networked so that product/process data and business manufacturing information can smoothly“flow.”A key manufacturing competitive advantage is not how well each system works but how well they all work together.Simplified hierarchiesIndustrial automation is changing from hierarchical Purdue models to more responsive architectures,achieving the goals of integrated real-time manufacturing.I wrote about the roots of this change in 2012 in an article titled“Simplifying Automation System Hierarchies.”Now,these architectures are being deployed at a growing rate to achieve more efficient and profitable manufacturing.New technology is making it possible to streamline this model to eliminate layers,increase performance,and lower software maintenance costs.The traditional strict hierarchy architecture is giving way to a more responsive and direct model to create real-time highly responsive manufacturing businesses.Field devices can communicate information directly with applications including historians,advanced cloud analytics,real-time maintenance monitoring,and other functions.This simplifies the applications of these functions and eliminates Level 2 and Level 3 software costs,complexity,performance drag,and ongoing software maintenance.Over the years,industrial automation architecture has been marked by increasing computing pushed toward final field devices,leveraging distributed computing to increase performance,quality,reliability,availability,responsiveness,and lower software maintenance costs.The limiting factor at each step has been the cost,ruggedness,and reliability of technologies.This has changed with significant commercial,consumer,and Internet of Things(IoT)technology and communications advances at low cost that are pervasive in daily life.The smartphonean everyday device many people possessis an AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 47 obvious example of a rugged,powerful computer with integrated communications and display.The most commonly used industrial automation architecture model to define manufacturing operations management is the five-level Purdue Reference Model(PRM),which later formed the basis for the ISA-95 standard.This five-layer hierarchical architecture served the industry well for years,being easily deployed with the existing available technology.The model is typically expressed as:Level 5:Business systems Level 4:Plant level(enterprise resource planning ERP,material requirements planning MRP,and manufacturing execution systems MES)Level 3:Operation unit Level 2:Machine/process automation Level 1:Controller Level 0:Sensor/actuator.Traditional automation systems generally reflect this architecture with software running on general-purpose computers at Levels 2,3,4,and 5.Levels 2,3,and 4 typically have database and communications interfaces that buffer and synchronize information between each level in addition to the associated human-machine interface(HMI)and user interfaces.The constraints of computing costs and networking bandwidth dictated this configuration based on past technology.The multilevel computing model is complicated,creating a great deal of cost,ongoing configuration control,and lifecycle investment.Fortunately,this model is changing to enable a more efficient and streamlined automation system architecture.Industrial manufacturing organizations have been eliminating the barriers between functional silos that create overlaps in processes and gaps in knowledge that impede collaboration,efficiency,and,ultimately,growth.Manufacturing companies are integrating AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 48 more tightly into the business,and this is also reflected by the integration of systems from sensor to enterprise.The transformation to integrated,real-time,data-driven manufacturing eliminates inefficiencies,increases responsiveness,increases profits,and encourages competitiveness.The shift to digital manufacturing architecture(DMA)is a fundamental building block for transformation that has implications from the enterprise level to the farthest end of manufacturing and productionsensing and control devices(Figure 1).This distributed system includes applications on embedded processors in sensors,actuators,barcode readers,cameras,and other field devices that can be controlled locally,but equally important,they can also be accessed remotely for complex calculations and adjustments at any time.This architecture allows for real-time transaction processing and synchronization with manufacturing,creating a closed loop.In addition to being highly integrated,effective DMAs:Provide immediate visibility throughout the entire enterprise Deliver unified,accurate,and timely data for decision making Adjust and optimize based on changes in supply chain and customer demand.In the new model,controllers can communicate information to all levels directly using the appropriate methods and protocols.Figure 1.Digital manufacturing architecture(DMA)optimizes and synchronizes internal and external production resources in real-time based on changing parameters.Digital Manufacturing ArchitectureSupply ChainCustomer Realtime Synchronized OptimizedAUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 49 Ethernet communication has become the high-speed and pervasive technology used by industrial automation protocols and business systems.More controllers are supporting multiple Ethernet ports to interact directly with industrial and business networks that exist throughout industrial plants.Historians,analytics,real-time maintenance monitoring,and other functions are now being incorporated into controllers.This simplifies the applications of these functions and eliminates traditional architecture software costs,complexity,performance drag,and ongoing software maintenance.More powerful controllers and communications enable the coordination between controllers without requiring a separate computer to coordinate them as well.The most effective architecture requires orchestrating and optimizing all elements of the process for flexibility in the face of external changes including supply chains,customer demands,costs,availability,energy,and sustainability requirements.The emerging DMA technology leverages advances in distributed computing and open systems to accomplish this and achieve synchronized,real-time,optimized production(Figure 2).Customer orders,supply chain factors,and factory operations are fed into the digital twin,an ideal operating model of the plant and its Figure 2.Digital manufacturing architectures allow for variability from the factory floor to the edge.Digital Manufacturing ArchitectureRealtime,Synchronized,OptimizedPlant&Process OperationsBusiness OperationsRealtime Closed Loop OperationsDigital TwinIdeal Operations ModelsHumanInterfacesIntelligentSensorsAnalyticsMIL,AI,.Edge ComputersAUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 50 processes.Real-time linkages throughout the system create a closed loop(Figure 3)with constant feedback,whereby analytics,artificial intelligence,and machine learning adjust and optimize operations.Digital manufacturing architecture requirements are driving industrial cybersecurity integration with mainstream information technology(IT),cloud,and IoT protection technologies and methods to create more secure manufacturing environments.Major technological advances include the incorporation of firmware/hardware in controller intelligent sensors,actuators,and other field edge devices.Real-time digital manufacturing is about becoming a more effective,holistic,and competitive business.This increases reliability,quality,production,profitability,safety,flexibility,informed decision-making,and overall competitiveness as a business.ABOUT THE AUTHORBill Lydon is editor emeritus of A and InTech magazine,publications from the International Society of Automation.He has more than 25 years of experience designing and applying automation and control technology,including computer-based machine tool controls,software for chiller and boiler plant optimization,and a new-generation building automation system.Lydon was also a product manager for a multimillion-dollar controls and automation product line,and later cofounder and president of an industrial control software company.He now acts as an industrial automation business coach and consultant on manufacturing digitalization and other topics.Integrated Realtime Manufacturing BusinessRealtime Closed Loop Benchmarking&OptimizingDigital Twin Ideal Operations ModelsEdge ComputingRealtime AI&Analytics Engine ChipsEnterprise&Cloud Business OperationsProduction Planning&ExecutionSupply Chain LogisticsAsset/MaintenanceManagementPeopleHMI,Mobile.SensorsPhysical,Video,LocationControlsPLC,DCS,Edge ComputersOtherPlant&Process OperationsAnalytics&AIFigure 3.Optimized closed-loop operations of all industrial functions.A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 51 AUTOMATION 2024 VOLUME 3In the world of industrial manufacturing,where operational technology(OT)systems control,automate,and keep mission-critical manufacturing processes safe,there has been a strong and steady push to adopt more open automation systems by employing modern software technologies that are already mainstream in the IT industry.Open Automation Systems Update on the State of the ArtBy Andre Babineau,John Conway,David DeBari,Alex Eaton,Kelly Li,Sarat Molakaseema and Josh SwansonExperts from UniversalAutomation.org,ExxonMobil,and other industry groups tell how modern software techniques are improving process automation systems.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 52 Some of the characteristics of these new open process automation systems are:Standardized communication protocols for improved interoperability of systems.Automation software that is decoupled from the hardware on which it executes,meaning the software applications essentially become vendor-independent.Object-oriented technologies for efficient creation and re-use of software component libraries.Event-driven architectures that simplify the integration of real-time automation systems and applications with other enterprise applications,such as analytics,asset management systems,and resource planning systems.Multiple benefits can be gained from these more open and modern approaches.To name just a few:1.Industrial manufacturers are better able to efficiently and more cost-effectively manage control system hardware end-of-life and obsolescence issues.2.Better return-on-investment as enterprises digitize and invest more-and-more in advanced application software.3.Using“proven-in-use”software components and standard IT infrastructure management tools increases the reliability of plant assets,as well as the cybersecurity and safety of the entire operation.Some characteristics of open process automation systems are standardized communication protocols,object-oriented technologies,event-driven architectures,and automation software decoupled from the hardware it runs on.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 53 4.Using best-in-class“Plug&Produce”software components increases innovation over the lifecycle of controlled assets.5.Enabling modular plants,modular machines,remote operations and other flexibility makes operations more agile and the global supply chain much more resilient.6.Last,but not least,attracting young software engineers into the automation profession to run the plants of the future with more modern technologies and architectures.This article summarizes the initiatives related to open automation and describes the technologies behind open automation architectures and the ExxonMobil Open Process Automation(OPA)test sites.Several major ongoing industrial initiatives/organizations today promote this new world of open automation software and the portability of industrial control applications.A few examples are:The Open Process Automation Forum,NAMUR,OPC Foundation,and UniversalAutomation.org Open Process Automation Forum.In late 2016,the Open Process Automation Forum(OPAF),an industry consortium,was formed by end users,vendors,suppliers,and academics within The Open Group to advocate for the definition of a highly standardized reference architecture for process automation systems,thereby allowing for the modular integration of products from multiple vendors into a single control system.This modular standardized architecture is achieved through the incorporation of existing standards and specifications wherever applicable,making the Open Process Automation Standard(O-PAS)a standard of standards.The diagram(Figure 1)outlines a sample AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 54 control system architecture using O-PAS components.A new OPAS system is centered around the use of Distributed Control Nodes(DCNs)which connect to a standardized and secure network backbone,the O-PAS Connectivity Framework(OCF).A DCN can provide a controller with logic-processing capabilities,an I/O module,or both(similar to a traditional PLC or DCS controller with attached IO).The OCF utilizes the OPC-UA communication protocol,allowing any connected DCN access to the data it needs across the network using a common,standardized data model.This availability of data across the OCF allows for the decoupling of I/O hardware from compute hardware,which provides greater flexibility in network design and easier extensibility when additional I/O or compute power is needed.O-PAS-compliant systems can also be integrated with existing control system offerings through the use of O-PAS Communication Interfaces(OCIs),which translate from other communication protocols into OPC-UA as used by the OCF.Figure 1.A sample control system architecture using O-PAS components.External Data Centers may run physical or virtual DCNs that are connected to the OCF through a firewall.On-PremiseOT Data Center(Executing IEC 62264 Level 2&3 Functions)ExternalOT Data Center(Executing IEC 62264 Level 2&3 Functions)EnterpriseIT Data Centers(Executing IEC 62264 Level 4 Functions)Stand-alone environments may be used for functions such as offline engineering and simulation.Physical I/O:AI,AO,DI,DO Twisted Pair,.OCI O-PAS Communication InterfaceBusiness Platform communicates through Apps running in a DCN,not directly to the OCFAdvanced Computing PlatformO-PAS Connectivity Framework(OCF)VirtualDCNVirtualDCNVirtualDCNVirtualDCNVirtual DCNDCNDCNDCNDCNDCNDCNDCNDCNDCNDCNDCNApplicationApplicationApplicationApplicationApplicationApplicationApplicationApplicationAPPAPPDCNDCNOCIDCSDCSPLCOCIPLCAnalyzerFieldNetworkInterfaceOCISafety,Electrical&MachinerySystemsNon O-PASEnvironmentsBusinessPlatformAPPAPPAPPAPPAPPAPPVirtualDCNAPPAPPDistributed Control Nodes(DCNs)(Executing IEC 62264 Level 1,2,&3 Functions)LegendO-PASConformantComponentNon O-PASConformantComponentAUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 55 Today(Q2 2024),OPAF has more than 120 corporate and academic institution members from across the world.OPAF working groups meet regularly to discuss business and technical initiatives and are currently working toward the version 3.0 release of the OPAF standard,with a focus on application portability and system orchestration.Additionally,OPAF has established liaison agreements with various groups in industry,such as the OPC Foundation,the International Society of Automation,NAMUR,and UniversalAutomation.Org to take advantage of parallel and complementary efforts within industry to standardize open automation platforms.NAMUR.NAMUR is an international user association of automation technology and digitalization in the process industries.The mission of the association is to contribute to the value generation of its member companies by helping to create efficient(costs,availability),sustainable,safe,and reliable processes.Believing that automation competence leads to reliable processes,NAMUR embraces a holistic approach to process technology,defining minimum requirements related to equipment and systems,fair dialogue with manufacturers,and the identification of future automation technology and digitalization requirements and development needs.NAMUR members positively influence regulations by cooperating in national and international standardization and including user AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 56 requirements.Members engage with standardization committees,authorities,and supervisory bodies to actively design industry standards and avoid non-economical and inappropriate standards for the industry.NAMUR also focuses on the future.To attract qualified engineering talent,NAMUR addresses issues that are relevant to process control,promotes advancements in practical applications,and represents the positive significance of automation technology and digitalization in the process industry.The NAMUR Open Architecture(NOA)enables plant and asset monitoring and optimization through easy and secure access to production data.Smart sensors,field devices,mobile devices,and the ubiquitous use of IT equipment are generating increasingly more data that can be difficult to access within the classic automation architecture.NOA is compatible with current developments in automation,such as the Advanced Physical Layer(APL)and the Module Type Package(MTP).NOA will enable a wide range of new use cases by opening and unlocking more data,which enables field devices,process analyzers,electronic equipment monitoring,mechanical equipment management,and optimization using additional process measurements and data.A detailed description of the NOA concept can be found in the NAMUR Recommendation NE 175.To accelerate productive solutions,NAMUR and ZVEI(the German Electro and Digital Industry Association)set up a joint project and several sub-working groups to drive the development of the different building blocks for NOA like MTP and APL.Modular production will play an important role in the process industry 4.0 transition and MTP embodies an interface and capability description of intelligent equipment modules via standardized equipment data models and description language.MTP provides a vendor-independent description of the process module with various facets,such as HMI,process control,maintenance,diagnostics,safety,and security,as well as alarm management,which reduces the time it takes to engineer and commission automation equipment modules.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 57 Many companies in the process industry are excited by the chance to access stranded data simply and securely and to use new monitoring and optimization functions.From the beginning of the NOA development,the NAMUR members have been involved with international organizations,such as BioPhorum and ISPE(International Society for Pharmaceutical Engineering)and presented the NOA concept at international events like those sponsored by the Open Group,since global acceptance is crucial for the success of NOA.OPC Foundation.OPC Unified Architecture(OPC UA)is an information exchange standard for secure,reliable,manufacturer-and platform-independent industrial communications.It enables data exchange between products from different manufacturers and across operating systems.The OPC UA standard is based on specifications that were developed in close cooperation between manufacturers,users,research institutes,and consortia,to enable consistent information exchange in heterogeneous systems.OPC UA is an IEC standard and is therefore ideally suited for collaboration with other organizations.As a global,independent,non-profit organization,the OPC Foundation coordinates the further development of the OPC standard in collaboration with users,manufacturers,and researchers.Activities include:Development and maintenance of specifications Certification and compliance testing of implementations Cooperation with other standards organizations.The OPC Foundation has launched the OPC UA FX(Field eXchange),an initiative that will further enable OPC UA adoption by covering the use cases and requirements for the field level.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 58 The goal of this initiative is to deliver an open,cohesive approach to implementing OPC UA,including time-sensitive networking(TSN)and associated application profiles.This will advance the OPC Foundation by providing vendor-independent end-to-end interoperability into field-level devices for all relevant industry automation use cases.The OPC Foundations vision is to become the worldwide industrial interoperability standard by integrating field devices with the shop floor.UniversalAutomation.Org.UniversalAutomation.Org(UAO)is a not-for-profit,international association established in 2021 to drive a vision of“plug and produce”automation using vendor-independent software components(think app store)that are enabled by the IEC61499 standard.The association is growing rapidly:As of June 2024,it has 89 members from the user,vendor,and academic communities.UAO believes“open automation”as it exists today is not open enough.It believes interoperable and portable application software is an essential enabler for Industry 4.0.In practice,UAO is a combination of two things:1.A standardized automation layer across vendors,based on the IEC 61499 standard,in the form of royalty-free license and runtime execution engine source code,which is available to its members on GitHub.2.An ecosystem of members from the user,vendor,and academic communities,who are committed to driving the adoption of the UAO runtime.UAO offers are available on the market and are being deployed by end users across various industry segments.For example,ExxonMobil and several other OPAF members use the UAO runtime as one of the components of their open-process automation architectures.Universal automation will allow OEMs,integrators,and end users to build automation solutions by plugging together best-of-breed apps using no-code graphical tools.In industry,we call this“plug and produce”.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 59 Much in the same way that consumers can easily access the latest mobile phone technologies and apps,industrial stakeholders,with plug-and-produce applications,will be able to experience ease of use at lower costs through much simpler,less labor-intensive behind-the-scenes integration.The IEC 61499 standard defines an event-driven architecture for distributed information and automation systems.It is object-oriented by design,and it establishes a clear separation between the application and the devices on which the application will execute.This combination of event-driven architecture,object-oriented programming,and hardware/software decoupling lays the foundation for plug-and-produce applications that are vendor-agnostic(Figure 2).Open Systems Performance Proprietary systems have done a great job bringing automation to where we are today.Defenders of proprietary systems argue they are required to achieve a high level of real-time performance and determinism.Figure 2.The IEC 61499 standard enables an event-driven architecture,object-oriented programming,and hardware/software decoupling that lays the foundation for plug-and-produce applications.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 60 While this may have been true 15 years ago,when compute power was expensive and open-source software systems were less developed,it is no longer true today.According to Moores Law,computer power continues to double every 18 months,and open-source software,like Linux,is already running mission-critical enterprise systems.Linux operating system.In the past,manufacturers typically used commercially available proprietary real-time operating systems.In parallel,the use of open-source Linux operating systems continued to expand,driven by the growth of the Internet and the associated data centers,to the point where the majority of internet traffic flows through Linux-powered systems.Linux is now being used extensively in consumer and industrial appliances that have embedded compute power.To meet the stringent requirements of control systems and other hard-deadline computing,a real-time patch for the Linux kernel scheduler was developed,prioritizing predictable performance.This has found use in industrial automation applications,as well as other embedded applications,providing the deterministic foundation for Linux to operate in control system environments.Today several industrial automation companies use Linux as the OS for their real-time control systems.Some examples include PLCNext from Phoenix Contact;ctrl X OS from Bosch Rexroth;ROS 2(Robot Operating System 2).Kernel-RT patches are available from vendors such as Canonical and Red Hat Because the real-time scheduling patches simply change scheduling behavior,all the other benefits brought by Linux are available to industrial workloads,such as portability,customization,and process isolation.In addition,Linux is being used as the foundation for next-generation offerings to meet or exceed existing embedded solutions.For example,Linux-based certified functionally safe systems are currently in development.Certification in both the industrial and automotive markets will be available for general consumption before the end of the year.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 61 Some vendors have even built high-availability(HA)solutions on top of a Linux platform,which when combined with network-based I/O,allows for failover to happen exclusively at the application level,without proprietary,expensive hardware.Automation platforms like PLCNext from Phoenix Contact and crtl X OS from Bosh Rexroth also promote the use of other apps programmed in multiple languages.And they even provide an app store with the possibility to download and run other apps alongside the real-time control apps.These systems typically have a common data layer through which different apps can access the system IO.Apps can be traditional control programs e.g.IEC 61131,or more modern programming languages such as C and Python.Mechanisms are in place to segregate real-time control applications from“right-time”applications,allowing the programmer to achieve the desired level of performance and determinism.The Bosch Rexroth ctrlX OS platform combines Linux with EtherCAT to address the very demanding multi-axis motion control AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 62 domain which requires a very high level of performance and micro-second determinism.The argument that Linux is not a“real-time OS”is clearly no longer true,as Linux has proven its deterministic capabilities,and is trusted in mission-critical applications by many different organizations,with more choosing it as the foundation of the next iteration of their solutions.Event-driven protocols and programming.Typical automation systems in the past used scan-based execution models and client/server or request/response communication models and protocols to ensure that the behavior of the control system was predictable and deterministic.Enterprise IT applications on the other hand had long ago switched to change/event-driven execution models and change/event-driven communications and protocols to leverage and monetize the benefits offered by the change/event-driven approach.In the recent past IT OT integration has received significant traction among end users seeking to integrate more and more their control systems with their enterprise applications.In these examples,they need to embrace and use the change/event-driven approach both in control execution and communications.A good number of control systems in the market today already support and use change/event-driven communication models and protocols in their products.Additionally,a good number of modern protocols,like OPC UA and MQTT,Ethernet IP,and Profinet,inherently support event-driven communication models.All or most of these protocols are already in use and supported in control systems in todays market.In line with the above developments,UniversalAutomation.Org(UAO)takes this one step further by applying the event-driven architecture to real-time control execution as defined by the IEC 61499 standard.To guarantee performance/determinism for demanding applications,resource-based prioritization is part of the UAO runtime.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 63 This allows a high-priority resource to interrupt lower-priority resources,ensuring that tasks requiring a rapid response time are executed in a predictable and deterministic manner.This is nothing new.Even scan-based systems have similar mechanisms to ensure that high-priority tasks can interrupt the general scan as and when required.The introduction of function blocks programmed in high-level languages such as C adds to the challenge of guaranteeing determinism,even in scan-based systems.Schneider Electric,one of the founding members of UAO recently demonstrated the deterministic performance of event-driven systems well below the millisecond level using the UAO resource prioritization mechanism on a Raspberry Pi running Linux.Despite running event chains that required more than 50ms to complete(matrix convolution calculations),higher-priority resources were able to interrupt the longer-running resource to execute the higher-priority tasks.A deterministic response in the range of a few hundred microseconds was achieved(additional technical details can be found here).In addition,event-based systems can implement“cyclic”tasks just like scan-based systems can.Reading of physical inputs is typically programmed as a high-priority cyclic task.Automation engineers with a background in traditional PLC programming indeed find it easier to understand scan-based systems compared to event-driven systems.However,the converse is also true:Young software engineers with experience in high-level languages struggle with scan-based systems.At the end of the day,at a low level,all systems are event-driven.Users must take care to ensure that their performance/determinism requirements are met.From Theory to Practice:ExxonMobil OPA Testing In 2016,ExxonMobil(an OPAF founding member)entered into a development agreement with Lockheed Martin to begin a proof of AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 64 concept for an open automation system architecture.In early 2017 they successfully used the IEC 61499 standard as a component for achieving that goal.Since 2018,several end users,with vendor support,have demonstrated their proof of concepts,prototypes,and test beds using IEC 61499-based control algorithms.ExxonMobil has extensively used IEC 61499-based control logic in their Open Process Automation Program since early 2017.The UAO Runtime has been tested extensively to prove that it has the capabilities to create reliable and predictable control logic applications.The first step for any user of IEC 61499 is to become familiar with the event-driven nature of the logic tools and the Execution Control Chart(ECC)capabilities.Once the user realizes that the system clock and a scheduled interval(e.g.,100ms,1sec,etc.)can be used as the event,the leap from purely time-based scan typical of IEC 61131-based products to event-driven execution in IEC 61499 is straight forward and enlightening.The freedom and independence from a specified,cyclical schedule offer new options for how to schedule and configure control logic applications that are more tailored to the actual process automation requirements.The standard of measure for companies like ExxonMobil includes the ability to safely automate,manage,and operate highly energetic chemical processes that are typically found in hydrocarbon refining and chemical manufacturing operations.The key criteria used for evaluating control systems and components include determinism,scalability,reliability,failure modes,and recovery,as well as a robust capability to implement existing and trusted process control code and methods,including the creation of new and novel control algorithms.This demonstrates that an open,standards-based,secure,and interoperable automation architecture will elevate the end users ability to improve business performance and success through modern technologies.AUTOMATION 2024 VOLUME 3A subsidiary of the InternationalSociety of Automation JULY 2024 AUTOMATION TRENDS REPORT 65 The usage of control logic in the UAO Runtime has been demonstrated and tested down to 1ms time cycles in a pilot plant prototype.While the responses from physical equipment,like valves and pumps,to control signal changes suffer from delay and deadtime that make 1ms timing impractical for general usage,the goal was to test whether control logic and the UAO Runtime based on the IEC 61499 standard,could be used for some types of rotating machinery timing requirements.The integration of basic control logic with Model Predictive Control(MPC)was also tested,demonstrating several orders of magnitude faster response(from 15sec to 40 msec)than in a legacy automation system.The advanced control algorithms were operated through connections to the PID logic blocks and directly communicated to the output I/O channels.Several end user companies have successfully repeated these use-case demonstrations in their prototypes and test beds and have gained confidence that IEC 61499-based products offer an excellent,standards-based choice for automation in an open architecture.The performance and capability of the IEC 61499 standard have
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2021 INSIGHT,INFLUENCE AND IMPACT 1IMPACTREPORT 2024makeuk.org125YEARSBACKINGBRITAINSMAKERS2021 INSI.
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IDEAS|PEOPLE|TRUSTIn partnership with:MANUFACTURINGOUTLOOKWith support from:and Manufacturing NI2024 QUARTER 4MANUFACTURING OUTLOOK 2024 QUARTER 42Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600MANUFACTURING OUTLOOK 2023 QUARTER 2MANUFACTURING OUTLOOK 2024 QUARTER 4Seamus NevinChief EconomistMake UKJohn Steinbecks Pulitzer Prize winning novel The Grapes of Wrath,narrates the displacement of the Joad family as they are forced to give up their farm due to the challenges of the Great Depression and the environmental devastation of the Dust Bowl.In the familys struggles and financial challenges,Steinbeck captures the stark realities of economic hardship,as farmers once full of hope find themselves crushed by circumstances beyond their control.Their journey reflects how external economic forces can burden even the most resilient,hardworking people.The Joads saga captures the social and political dynamics of the time,but its sentiments speak to many farming families feeling battered by new fiscal burdens today.While most media coverage of the Autumn Statement has focused on British farmers,manufacturers too are grappling with external pressures and cost increases that threaten to pull them under.As this quarters Manufacturing Outlook survey shows,family firms once buoyed by optimism,may find themselves struggling to stay afloat.Though recruitment and investment intentions remain stable,the mood among companies has darkened markedly since the Chancellors Autumn Statement.Confidence among UK manufacturers has dipped sharply to the lowest level in a year.That contrasts sharply with our previous Make UK/BDO survey when almost six in ten companies(58%)were looking ahead to a brighter future under a new government with its clear commitment to a modern,long-term,industrial strategy.Last quarter,optimism among manufacturers reached one of its highest levels in a decade.Overall conditions were beginning to improve,with output and order volumes gradually rebounding.The Budget put paid to that positivity.The increase in payroll costs,in particular(employers)National Insurance and the National Minimum Wage,coupled with capital gains and Inheritance Tax changes,as well as general pessimism about the state of the UK economy have all had an impact across the sector.The budget was always going to involve tough choices.However,there is no escaping the fact that the surprising change in NICs thresholds,at a time of other cumulative increases in costs associated with the National Living Wage,Apprenticeship Levy and other policies is causing many to think twice about pay rises and investment in new equipment.70%of manufacturers have already seen their cost base grow by a fifth this year.Almost one in ten(8%)saw them increase by up to a half.Now,almost nine in ten companies(86%)expect to see their payroll costs increase due to the Make Work Pay reforms,with almost half of companies(44%)saying this increase will be significant.The cumulative effect looks likely to make investing in growth and the green transition much more difficult.The Great Depression discussed in Steinbecks novel was ended by President Franklin D.Roosevelts New Deal.The new UK Labour Government was elected with an offer of a new deal of its own.It promised to deliver supply-side reforms-deregulating planning,shouldering more of the risks to help invest in and grow British businesses,and providing the long-term policy and planning stability that manufacturers need to succeed-but,in return,business must increase investment in digitalisation and Net Zero,and respect the New Deal For Working People.With domestic market demand relatively weak,and input prices being pushed up,there is an urgent need for Government to move forward measures to mitigate the negative growth manufacturing firms are now facing.FOREWORDRichard AustinHead of Manufacturing BDO LLP3MANUFACTURING OUTLOOK 2024 QUARTER 4Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Business performanceUK economic conditions3.003.504.004.505.005.506.006.507.007.508.002022q32022q42022q22022q12021q42021q32021q22021q12020q42020q32020q22020q12019q42019q32019q22019q12018q42018q32018q22018q12017q42017q32017q22017q12016q42016q3Jul-162016q22016q12015q42015q32023q32023q42023q22023q12024q12024q22024q32024q4Manufacturers optimism dips for the first time since Q4 2023.Confidence in the next 12 months 1=substantially worse,10=substantially betterSource:Make UK Manufacturing Outlook SurveyMake UKs Q4 2024 Manufacturing Outlook report,in partnership with BDO,reports a return to stable growth for output and orders.However,growing signs of weakness in the domestic market continue to slow industrial activity as rising costs have impeded growth expectations.As a result of a mixed year,the manufacturing industry expected its gross value-added output to decline overall in 2024.The latest balance of output reported at 20%,up from-2%,indicating that industry production expanded for a large share of businesses following the unexpected contraction last quarter.The last time output grew for this many manufacturers was the fourth quarter of 2023 which could suggest a return to regular growth during the festive periods.However,whether this rate of growth will continue into 2025 is far more difficult to predict given how the business cost environment will change next year.Manufacturers already predict that the balance of output will drop to 15%for the first quarter of 2025.The sobering of future expectations could be a welcome change for the industry that has grown accustomed to overestimating its future performance.Albeit,as the expectations for production have been reduced,manufacturers expect their orders books to continue improving.In this latest chapter,the balance for total orders reported at 7%,unchanged from last quarter and a balance of 16%of manufacturers expect their orders to improve further in Q1 next year.However,it should be noted that these businesses have overestimated their order books for seven quarters in a row now.HEADLINESis loosening.As it stands,it is unclear what the impact of higher employers National Insurance contributions will be on recruitment plans.Investment intentions maintained a balance of 10%,adding to the view that economic stability and stronger policy incentives have supported productive investment decision-making.The share of businesses raising prices is mixed for UK and export goods.The domestic market has reported a slight increase of the balance to 25%,indicating domestic inflationary pressures have accelerated.On the flip side,export price rises have reduced in balance to 21%,indicating easing inflationary pressures.However,margins have improved in both categories with a lower balance of manufacturers reporting contractions.For the first three quarters of this year,confidence levels in both business conditions and economic conditions have consistently moved upward despite quarter-on-quarter turbulence.However,for the final quarter,confidence has dipped,suggesting a deterioration of expectations for the future,as is also reflected in manufacturers output forecast.The standout change is that confidence in UK economic conditions has fallen at its sharpest rate since Q2 2020,declining by 1 point,or in other words 15%down,compared with the previous quarter.Despite this,confidence overall remains positive,but the contraction of this quarter may be a sign of more to come considering incoming rises in business costs in 2025.The modest growth in total orders is primarily down to flourishing export orders that have supported the growth of businesses during turbulent times and reported a balance of 10%this quarter.However,the weakness in the domestic market has persisted now for six quarters in a row,reporting a balance of 0%,with limited signals of a recovery in 2025.The strength of any rebound will depend largely on several factors including the real impact of the Governments Autumn Budget,the movement of interest rates and inflation and the severity of returning President Trumps impact on global trade.The question now is for how long a strong export market can sustain the sector until the domestic market improves.This quarters employment and investment metrics are characterised by positive stability.Despite the former having indicated a decline in the third quarter,it was always within our expectations that recruitment would grow again,reporting a balance of 8%.Nevertheless,the number of live vacancies in the industry is returning to its long-run average indicating that the labour market INDICATORBALANCECHANGEConfidence6.5Optimism slows for the first time since Q4 2023 but remains positiveOutput20%Output volumes rebound following dipUK orders0%Domestic market orders flat but improvedExport orders10%Exports slow marginallyEmployment8%Employment contracts for the first time in four quartersInvestment10%Investment intentions remain stableSource:Make UK Manufacturing Outlook SurveyMANUFACTURING OUTLOOK 2024 QUARTER 44Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600OUTPUTServing as somewhat of a saving grace for the sectors year average output performance,the output balance figure for the final quarter of the year brings about encouraging growth after a past year characterised by single-digit performances.Despite not quite reaching the heights of expectation that were set for this quarters performance,performance in output hasnt been this positive since the same time last year.The balance figure for order books was not particularly strong in the previous quarter,leading our analysis then to conclude that we would be less likely to see the kind of growth in output performance that we have,given there was little evidence of growing demand for the sectors products between Q3 and Q4.Nevertheless,those conclusions have been subverted by markedly impressive performance in the face of a pedestrian order performance throughout most of the year.Despite this,the twin effects of sustained industrial confidence and the slow and steady loosening of monetary policy will have played their part.Over the past year,perhaps even two,there has been a degree of pent-up demand as the relative cost of capital remained elevated and was set against a backdrop of political uncertainty.Now,with those concerns mostly abated for the time being,activity has started gathering momentum once more.PAST THREE MONTHS20%NEXT THREE MONTHS15%This quarters balance figure for output stands at 20%,a significant improvement over last quarters-2%.Given the single-digit output performance weve observed throughout the year so far,this final quarter boost certainly helps to paint a prettier picture of the sectors year average,even though despite this last-minute boon it will remain insufficient to outperform 2023s output average,which saw double-digit output performance in three out of its four quarters.The largest of companies,as proxied by turnover,have experienced the greatest uptick in output this quarter,with the middle market and small firms faring about equal.What is of particular note is the sectors next-quarter expectations.Followers of Manufacturing Outlook may have noted that the industry has exhibited demonstrable over-confidence in every quarter for just over a year,that is in the sense that the sector has expected output to grow in the future-3 month metric by significant degrees,although when the quarter comes to pass the exceptionally positive ambitions fail to materialise.SECTORPAST 3 MONTHSNEXT 3 MONTHSBasic Metals*Metal Products20%-9%Mechanical234%Electronics10%Electrical26%Rubber&Plastics-186%TURNOVER0-9m9-24m10%m and over213%Output summarylance of changeSource:Make UK Manufacturing Outlook Survey*insufficient sample this quarterOutput volumes rebound following a contraction in the previous quarter%-80-60-40-200204060Next 3 months2022q32022q42022q22022q12021q42021q32021q22021q12020q42020q32020q22020q12019q42019q32019q22019q12018q42018q32018q22018q12017q42017q32017q22017q12016q42016q32016q22016q12015q42015q32015q22015q12023q22023q32023q12024q12023q42024q32024q22024q4lance of change in outputSource:Make UK Manufacturing Outlook SurveyNow,with an expectation of a 15lance figure for output in the first quarter of 2025,it would appear expectations have sobered,and perhaps become more grounded.5MANUFACTURING OUTLOOK 2024 QUARTER 4Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600ORDERSFollowing the sharp slowdown in order books in the third quarter of this year,there is a growing concern amongst manufacturers that demand will not return to anywhere near the levels seen in 2021.Furthermore,the return of President Trump presents the risk that seismic shifts in global trade flows could take place over the next year.The impact this could have on the UK is currently unknown,but the National Institute of Economic Research(NIESR)estimates that UK GDP could fall by 0.7%in 2025.This would be problematic for the manufacturing sector which has been graced by robust demand from overseas,particularly from the European Union and North America regions.As UK market conditions have faced persistent uncertainty over the last twelve months,it is important for businesses to be able to rely on a diverse customer base to protect margins.This is challenging in the current policy climate following the reveal that several business taxes will increase,including employers National Insurance and potentially Business Rates.Total orders reported a 7 balance this quarter,a repeat of the result from Q3.This stable performance is largely related to a slight improvement in domestic market orders which was balanced by a slight slowdown in export orders.The latter remains the best performer of the two measures of pipelines.The balance for total orders highlights an important relationship between domestic and international markets,and how critical supply chains are connected.In order to generate real material growth in the industry,it is imperative that both UK and export orders grow,rather than relying on contractions in one area to be offset by growth in another.Additionally,manufacturers continue to overestimate their future total orders performance,reflecting the uncertain operating conditions many are working in.It is the seventh quarter in a row that manufacturers have underperformed on their expectations for new work.However,for the first time this year,manufacturers have forecast export orders to slow in the coming months suggesting businesses are factoring in geopolitical changes into their current expectations.UK ORDERSFor the last six quarters in a row,the balances for UK orders have been concerningly poor.Albeit the flow of new work from domestic consumers is nowhere near the level of contractions experienced during the height of the pandemic,the lack of growth leaves something to be desired for a sector that is repeatedly being asked to invest more.The latest balance of 0%is an improvement on the previous quarters-4%,though market conditions remain weak.UK ORDERS PAST THREE MONTHS0%NEXT THREE MONTHS8%EXPORT ORDERSPAST THREE MONTHS 10%NEXT THREE MONTHS7%TOTAL ORDERSPAST THREE MONTHS 7%NEXT THREE MONTHS16%Domestic market performance flat as exports remain positivelance of change in ordersSource:Make UK Manufacturing Outlook SurveyUK ordersExport ordersTotal orders2022q32022q12021q32021q12020q32020q12019q32019q12018q32018q12017q32017q12016q32016q12015q32015q12023q12023q3-60-50-40-30-20-1001020304050Next 3 months2024q12024q3The results for the sub-sectoral breakdown for UK orders for some producers of intermediate goods are also worrying.The electronics subsector reported a balance of-30%,far more negative than the national average.MANUFACTURING OUTLOOK 2024 QUARTER 46Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Additionally,metal products also reported a negative balance.On a more positive note,rubber&plastics,electrical engineering and mechanical equipment all reported marginally positive balances which suggests industries such as construction may be experiencing growth.EXPORT ORDERSExports continue to boost total orders for the manufacturing sector,reporting a balance of 10%for the quarter.However,this is a marginal slowdown from the 11lance in the third quarter.The potential concern for the industry is that manufacturers expect exports to slow down further in the first quarter of next year,with only a 7lance of manufacturers expecting growth in exports.This may reflect the impact that potential US tariffs could have on critical subsectors such as automotive.Subsector-wise,of the manufacturing subsectors that are considered to be producers of intermediate goods,only the electronics industry reported a negative balance.Finally,the survey finds that activity remains strong from the EU,with 52%of UK manufacturers reporting positive demand conditions from the region,slightly lower than last quarters 55%.76%of manufacturers in the metal products industry have reported strong demand conditions in the EU,whilst mechanical equipment is fairing quite well in both the EU and North America.The top three are completed by North America and Asia as expected.Demand conditions for processed metal strong in Europe%AsiaEuropeNorth America01020304050607080ManufacturingRubber&PlasticsElectrical ElectronicsMechanicalMetalProductsSource:Make UK Manufacturing Outlook Survey%of companies reporting positive demand conditions by marketUK ORDERSEXPORT ORDERSTOTAL ORDERSSECTORPAST 3 MONTHSNEXT 3 MONTHSPAST 3 MONTHSNEXT 3 MONTHSPAST 3 MONTHSNEXT 3 MONTHSBasic Metals*Metal Products-2%-5%-4%0%Mechanical8$%8%Electronics-30%-10%-14%-30%0%Electrical 5!%0%9%4%Rubber&Plastics9%066%TURNOVER0-9m-7%4%-6%1%1-24m-8%2%-9%-4%0%m and over8%3)%&%Source:Make UK Manufacturing Outlook Survey*insufficient sample for export ordersOrders summarylance of change7MANUFACTURING OUTLOOK 2024 QUARTER 4Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600EMPLOYMENT&INVESTMENTThe quarters employment and investment metrics in the years final Manufacturing Outlook are characterised by positive stability in both cases,but the implications of stability in investment intentions remain a disappointment.Employment has returned to growth following marginal negativity in the previous quarter,but the wider story lies in how aggregate vacancy figures in the sector continue to steadily cool back to their long-run average,indicating that the severity of the labour shortage for the sector is continuing to cool from the persistent labour market disruption that the pandemic brought about in 2022.The employment balance figure this quarter stands at 8%.While an encouraging figure that isnt too expansionary,it reflects a change in pace from what we observed last quarter where it stood at-1%.Having been at similarly positive levels in the first and second quarters of the year as to what is reported in this edition,the third quarter negativity served as a blip that highlighted nervousness within the industry about cost control.A balance figure of-1 implies that,on aggregate,the sectors behaviour was tantamount to a hiring freeze.When we observe this and dont notice a significant drop in vacancies at the same time,we can surmise that there is not a proclivity to hire,at least in the short term,despite roles still being required by the sector in the medium term.Looking forward,the sector has posted an expectation for an employment balance of 19%for the first quarter of next year.Investment intentionsEmployment%-40-30-20-1001020304050Next 3 months2022q32022q42022q22022q12021q42021q32021q22021q12020q42020q32020q22020q12019q42019q32019q22019q12018q42018q32018q22018q12017q42017q32017q22017q12016q42016q32016q22016q12015q42015q32015q22015q12023q12023q22023q32023q42024q32024q12024q12024q4Employment growth recovers as investment remains stableSource:Make UK Manufacturing Outlook surveylance of change Unlike other metrics in Manufacturing Outlook,the future-looking employment metric is typically representative of manufacturers intention to hire,rather than their belief that they will render that employment growth in just three months.If anything,it more closely reflects the average severity of the labour shortage in the market over anything else.As of October 2024,there were 56,000 live vacancies in the UKs manufacturing sector,a decrease from the 62,000 that were reported in the previous quarters edition of this report.However,if we factor in ONS revisions in the intervening period,the revised figure for July is closer to 58,000,indicating a reduction of vacancies between the third and fourth quarter of the year by approximately 2,000.As a ratio,that is for every hundred jobs in the sector,2.3 are vacant,down from 2.5 in last quarters report,but down from 2.4 based on revised ONS data for the same time period.The vacancy ratio data for the sector dates back to 2001,and the long-run average for the ratio,pre-pandemic(i.e.2021),stands at approximately 1.8.Since the peak of 4.0 in late 2022,this ratio has been steadily reducing,albeit over a long period of time,lending strong evidence as to the easing of the severity of the industrys labour shortage.Nevertheless,its important to acknowledge that this easing in the acute labour shortage exacerbated by the pandemic should not be conflated with the ongoing systemic challenge of skills shortages within the sector.The investment intentions metric measures the sectors intentions to invest in the coming 12 months.This quarters balance figure has come in at the same level as the third quarter of the year,at 10%.EMPLOYMENTPAST THREE MONTHS8%NEXT THREE MONTHS19%INVESTMENTNEXT TWELVE MONTHS 10%EMPLOYMENTINVESTMENTSECTORPAST THREE MONTHSNEXT THREE MONTHSNEXT TWELVE MONTHSBasic Metals*Metal Products4%Mechanical151%5%Electronics-20 %0%Electrical 9&%Rubber&Plastics0%9%TURNOVER0-9m11-24m-11%2%-2%m and over13(%Employment and Investment summarylance of changeSource:Make UK Manufacturing Outlook Survey*insufficient sample for export ordersWhile it is still a positive figure,and a double-digit one at that,there is still some nuanced negativity associated with that result.The investment intentions balance has remained in this moderately positive position for five quarters now,deviating little from approximately 10%.Despite this,in this period the UK economy has seen a new government,the imposition of significant pro-business investment policies(e.g.full expensing)and the slow but steady reduction in the cost of capital as per the Banks base rate.However,despite all these factors that would lead to the expectation of improved investment intentions,none have manifested,at least in the aggregate balance figure data as shown.MANUFACTURING OUTLOOK 2024 QUARTER 48Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600PRICES&MARGINSAcross the first and second quarters of the year,the Manufacturing Outlook survey reported that,as per our price-setting behaviour metrics,inflation in manufacturers supply side had been building.This was particularly alarming as it was set against a backdrop of steadily falling input price growth for the four quarters prior,coming down from the highest levels ever recorded in this publications over thirty-year history.The peak came in the data in the first quarter of 2022,spurred on initially by a bounce back in demand following the pandemic,subsequently being sustained by the energy crisis that saw producers input costs remain elevated.Since the first half of the year,namely in the third quarter,price-setting behaviour returned to a slower growth rate in line with the two-year trend.Its important to note that our data does not suggest prices are in absolute remission,rather they suggest that the rate of growth of prices is slowing.This quarters data sees an increase in the balance figure for domestic prices compared to last,indicating a greater proportion of manufacturers have raised their prices this quarter.However,for export prices,the rate of cooling has continued,albeit more slowly than hoped.The balance figures of UK prices and export prices are 25%and 21%respectively,an increase in UK prices by 5 percentage points and a decrease in Export prices by 2 percentage points relative to last quarter.While these arent massive swings,they come at a time when the wider trading environment would suggest that prices should be cooling much faster,as is the trajectory of the Bank of England which has been steadily reducing the base rate,currently standing at 4.75%,throughout the year.These results could slow down the pace of base rate reductions in 2025.However,the data suggests that the elevated price rises have enabled an improvement in margins,despite them remaining in marginal negativity.The UK margins and export margins balance figures reported at-4%and-1%respectively.A 6 percentage point increase in the case of UK margins and a 3 percent increase in the case of Export margins.There are expectations from the sector for growth in both prices and margins by the first quarter of the year,with bittersweet implications.In the first instance,manufacturers expect the UK prices balance figure to rise by 5 percentage points to 30%,and by 12 points to 33%for export prices.If price-setting behaviour does increase when we receive the data in the first quarter of next year,that would represent two consecutive quarters of acceleration in domestic price increases,indicating that the inflationary beast hasnt quite been put to bed,likely having bearish implications for monetary policy decisions in the first half of next year.The sweet is seen in the margins,as the sector expects margins to turn to positivity in the first quarter of 2025,with balances of 4%and 5%for UK margins and export margins respectively.If UK PRICESPAST THREE MONTHS25%NEXT THREE MONTHS30%EXPORT PRICESPAST THREE MONTHS 21%NEXT THREE MONTHS33%UK MARGINSPAST THREE MONTHS-4%NEXT THREE MONTHS4%EXPORT MARGINSPAST THREE MONTHS-4%NEXT THREE MONTHS5%Export prices for materials and construction riseDomestic inflation accelerates as business costs increaselance of change-40-30-20-100102030405060Next three months2022q32022q42023q12023q22023q32022q22022q12021q42021q32021q22021q12020q42020q32020q22020q12019q42019q32019q22019q12018q42018q32018q22018q12017q42017q32017q22017q12016q42016q32016q22016q12015q42015q32015q22015q1 23q42024q12024q32024q22024q4-40-30-20-100102030405060UK prices(LHS)UK margins(RHS)Export prices(LHS)Export margins(RHS)Source:Make UK Manufacturing Outlook Survey%Rubber&PlasticsElectricalEquipmentElectronicEquipmentMechanicalEquipmentMetalProductsBasicMetals*2024q32024q401020304050607080Source:Make UK Manufacturing Outlook Surveylance of change in export prices in the past three months*insufficient sample for Q4balance figures for margins do turn positive in the next quarter,this would be the first time they have done so since the tail end of 2021.Alas,in recent quarters it has been all too common for the sector to suggest that margins will just tip into positivity in the coming quarter,but when the quarter comes the reality falls just short time and again.9MANUFACTURING OUTLOOK 2024 QUARTER 4Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600ScotlandNorthEastNorthWestNorthernIrelandYorkshire&HumbersideEastMidlandsEast ofEnglandSouth WestWalesWestMidlandsSince early 2021,manufacturers have continued to demonstrate resilience in their optimistic view of business conditions.Of the last seven quarters,NATIONAL®IONAL6.6 6.96.66.26.8 6.6 6.2 6.2 KEY:/INCREASE/DECREASE ON PREVIOUS QUARTEROUTPUTEMPLOYMENT INVESTMENT BUSINESS CONFIDENCEThe map is coloured according to the business confidence levels difference from average UK business confidencebusiness confidence has improved six times highlighting the sectors unshakable belief that things will be better in the future.This is unsurprising given the relative 6.86.0Source:Make UK Manufacturing Outlook SurveyHIGH CONFIDENCELOW CONFIDENCELondon&South EastMANUFACTURING OUTLOOK 2024 QUARTER 410Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600business conditions most companies are operating in today are far better than those experienced over the last few years,such as trading uncertainty,supply-chain disruption and astronomically high energy prices.However,this persistent climb in optimism has unexpectedly reversed its trajectory for both business and economic conditions.This is an indication that expectations for the future could fall,which will undoubtedly impact investment given confidence is regularly highlighted as the number one factor in capital expenditure decision-making.Nevertheless,there is a possibility that investment could move in a different direction as the rising cost of employment could instigate a push towards greater automation and digitalisation.The likelihood of this happening will depend largely on the ambition and quality of implementation of the governments upcoming industrial strategy,Invest 2035.Headline business confidence reported at 6.5,which is down from last quarters level of 7.1.All regions and nations reported above the 5 inflexion point that separates positive and negative confidence.This indicates that on average,most manufacturers are relatively in line in terms of their optimism levels for the next 12 months.Across the nation,excluding Northern Ireland,seven regions or nations have reported a decrease in their business confidence.Amongst the English regions,the largest improvement in business confidence was reported by the North East,which increased by 0.6 points to 6.8.However,the most confident region in the UK is Yorkshire&the Humber reporting a business confidence level of 6.9.The only other regions to report improved business confidence levels include the South West(up by 0.7)and East Midlands(0.2).All other English regions reported declines in business confidence,the biggest contraction was reported by the South East&London region(down 1.2).This is followed by the North West which declined by 0.9.Outside of the English regions,however,Welsh business confidence dropped by a more significant 1.6 points.As a result,Wales also has relatively the lowest business confidence in the UK.It should be noted that despite the direction of change being primarily down,manufacturers generally remain optimistic about their own business conditions.012345678910BusinessUK economyUK average*WestMidsSouth East&LondonEastMidsNorthEastSouthWestEasternNorthWestYorks&HumberScotlandWales*Average=/=component parts due to instances of undeclared regionalitySource:Make UK Manufacturing Outlook Survey.All UK regions and nations report positive business confidenceConfidence in the next 12 months 1=substantially worse,10=substantially betterUK ECONOMY CONFIDENCEManufacturers confidence in the overall UK economy reported at 5.8,this is a one-point decline from the previous quarters level(reporting at 6.8).Relatively speaking,the sharpness of this negative change is unexpectedly the largest since the second quarter of 2020.During the first half of the year,many businesses raised their expectations for the UK economy believing that growth would return.Many international forecasting bodies such as the IMF had raised their prospects for the economy due to tailwinds that put the UK in a competitively advantageous position.However,a rise in political uncertainty and the growing risks of higher business costs have likely spoiled manufacturers hopes of achieving real growth.As a result,expectations for the UK economy appear to have declined at their fastest rate since the pandemic era.Fortunately,the average confidence for the UK economy remains positive(above 5)but the impact of new legislations to employment rights and increased cost of employing staff could potentially hit investment and R&D activity.11MANUFACTURING OUTLOOK 2024 QUARTER 4Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600OUTPUTTOTAL ORDERSEMPLOYMENTREGIONPAST 3 MONTHSNEXT 3 MONTHSPAST 3 MONTHSNEXT 3 MONTHSPAST 3 MONTHSNEXT 3 MONTHSScotland1017-3101426North East*605060601020North West-66226-1117Yorks&Humber*47532767020East Mids120-6-1200Eastern515010-14-5South East&London72673127South West130707-20West Mids050331429Wales86-2929-2943-29Regional summarylance of changeSource:Make UK Manufacturing Outlook Survey*Sample size relatively low for these regionsMANUFACTURING OUTLOOK 2024 QUARTER 412Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600ECONOMIC ENVIRONMENTHalfway into the new Governments first year in power,the manufacturing sector has experienced a plethora of opportunities and challenges.The“mission”for growth is now firmly on the minds of every civil servant who are tirelessly formulating the right level of support for industry to restart the flow of investment whilst resetting the public purse to ensure the nations financial health.However,this has put the Government in an inconvenient position as promises of long-term strategies to install confidence have been overshadowed by an increase in the business tax burden,driven by short-term needs.Manufacturers remain resilient in the face of novel challenges,though the change in employers National Insurance contributions(NICs)and adjustments to Capital Gains Tax and Inheritance Tax will be a difficult pill to swallow following several years of disruption and higher costs.There is hope that the background work ongoing for the industrial strategy,Invest 2035,will rebalance the scale in industrys favour.The most recent string of GDP figures published by the Office of National Statistics(ONS)already suggests the UK economy had a difficult third quarter.Growth between August and September reported at-0.1%,driven by a decline in production and manufacturing whilst services and construction reported no growth.Across the quarter the UKs performance was flat following the immediate aftermath of the general election,suggesting the first change in government in 14 years did little to set ablaze consumer confidence.According to Oxford Economics,it is likely the UK will now achieve less than 1%growth overall in 2024 if the current trajectory continues.However,alternative bodies like the IMF are slightly more optimistic expecting the UK to grow by 1.4%this year.The positive note is that manufacturing has not been the main contributor to the poor GDP performances lately.Within the production sector includes the generation of electricity,gas,steam and air conditioning which contracted by 2.7%in the third quarter,whilst manufacturing grew overall by 0.2%.However,this is still a concerningly low level of growth for the industry.Our previous economic outlook indicated this was primarily down to a slowdown in domestic market orders that have negatively impacted the industrys prospects.International forecasts highlight that two major economic nations,Germany and Japan,expect to contract overall in 2024,though likely for different reasons.Germany has faced major issues due to high energy costs negatively impacting the countrys largest industrial sectors,such as automotive and capital equipment producers.Japan is experiencing persistent positive inflation for the first time in decades which has negatively impacted consumer confidence.The US continues to expect strong growth,though it is unclear currently how returning President Trumps tariffs will affect US businesses.Despite the incoming rise in business costs,particularly due to the planned changes in employers NICs and legislative changes in employment rights,manufacturers still hope to see interest rates fall in Jan-22Feb-22Mar-22Apr-22May-22Jun-22Jul-22Aug-22Sep-22Oct-22Nov-22Dec-22Oct-23Nov-23Jan-23Feb-23Mar-23Apr-23May-23Jun-23ServicesManufacturing and Other ProductionConstructionGDP-1.0-0.8-0.6-0.4-0.20.00.20.40.60.81.01.2Jul-23Aug-23Sep-23Dec-23Jan-24Feb-24Mar-24Apr-24May-24Jun-24Jul-24Aug-24Sep-24Source:ONSGDP fell in September due to a slowdown in manufacturingContributions to monthly GDP,percentage points,January 2022 to September 202413MANUFACTURING OUTLOOK 2024 QUARTER 4Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 66002025 for balance.Higher rates have been highlighted as a significant barrier to investment since they were raised from their historically low levels in the last decade.However,the rate of consumer inflation,which the central bank targets at 2%,remains persistently higher than expected.The latest report of 2.3%inflation was unwelcome news to many consumers who are hoping for stronger signals of rate cuts in the next year,though the rise in prices is primarily down to Ofgem raising the price cap for energy bills.Producer inflation is on a downward trend,and reported a-2.3cline for inputs in the ONS latest survey.Factory gate prices reported at 0.1%,which whilst small indicates manufacturers are raising prices to recoup lost margins.The overall economic environment is a mixed one for manufacturers.The change in government presents an opportunity to renew hope across industries though not enough detail on strategies has been revealed to move the needle on investment decisions.Nevertheless,following the investment summit,which saw the CEO of Microsoft named as Chair of the Industrial Strategy Council(ISC),sends a strong message to the global economy about how the UK expects to evolve over the next decade.The future is inevitably going to centre on AI and the mass adoption of digital and automation technologies to close the productivity gap.Manufacturers will have a role to play in this transition but those businesses that fail to move in line with this progress may find themselves falling behind.Source:Oxford Economics and Make UKUK Economic Forecasts%change except where stated202320242025TRADING ENVIRONMENTExchange rate(/)1.151.21.2Exchange rate($/)1.271.261.27Exports-0.3-1.91.9Imports-1.32.52.2Current account(%GDP)-2.6-3.1-2.8OUTPUT Manufacturing1.1-0.20.7GDP0.30.91.4COSTS AND PRICESAverage earnings7.45.03.5Oil price(Brent Oil$/bl)828073EMPLOYMENTManufacturing(000s)2,603 2,579 2,552 Rest of economy(000s)36,689 37,094 37,338 Unemployment rate(%)4.14.34.4GDPINFLATION202320242025202320242025US2.52.82.64.12.92.4Eurozone0.50.81.21.92.31.6France0.91.10.84.92.01.3Germany-0.2-0.10.65.92.21.2Japan2.0-0.11.23.32.51.5China5.24.84.40.20.21.3India 7.06.86.85.74.74.5World(US$weighted)2.72.72.86.04.53.5International Economic Forecasts%changeSource:Oxford EconomicsMANUFACTURING OUTLOOK 2024 QUARTER 414Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600FOOD&DRINKThe Food&Drink subsector continues to dominate UK manufacturing,accounting for 21.3%of the total GVA,a figure increased by 0.1%from the previous quarter.Forecasts for output in 2024 remain robust at 2.9%,indicating that the subsector is maintaining its growth trajectory despite the gloomier outlook as illustrated by the manufacturing sector average growth expectation of-0.2%in the same period.Growth in 2025 is expected to be a more moderate 0.8%.Employment,however,presents a mixed picture.While relatively stable,it is forecast to decline slightly by-0.2%in 2024,followed by a sharper drop of-1.5%in 2025.ELECTRONICSThe Electronics subsector is the only subsector that is forecast a perfectly flat growth expectation for 2024.Output growth in 2024 is forecast to remain at 0.0%,although relative to the average,this forecast is slightly ahead of the pack.For 2025,the subsector is expected to regain some momentum with a modest growth forecast of 0.9%.On the employment front,the subsector demonstrates consistency across output and employment,with a slight increase of 0.1%projected for 2024.However,this is subsequently expected to be followed by a decline of-1.7%in 2025.BASIC METALS AND METAL PRODUCTS The Basic Metals subsector remains under significant pressure,reflecting the disruption in global commodity markets,particularly that of demand cycles and SECTOR FORECASTING 2024 Q40510152025%share of manufacturing GVAElectricalBasic metalsNon-metallic mineralsRubber&plasticsOther transportTextilesChemicalsPaper&printingMotor vehiclesElectronicsMetal productsPharmaceuticalsMechanicalFood&drinkSource:Oxford EconomicsQ4 2024 manufacturing sector composition by GVA(%share)Subsector share of Manufacturing Gross Value Addedgeographic sourcing decisions.Output is forecast to decline by-2.2%in 2024.This contraction is set to continue in 2025,with output expected to fall sharply by-11.5%.Employment in the subsector mirrors this bleakoutlook,with workforce reductions of-1.5%anticipated in 2024 and a dramatic-8.3cline forecast for 2025.These figures highlight the subsectors vulnerability to macroeconomic headwinds and higher domestic marginal costs of production.The Fabricated Metals subsector is now almost inverse to the Basic Metals subsector,despite their inherent linkage.The output forecast for 2024 is significantly above the sector average,with growth in output of 7%forecast,an improvement over last quarters forecast.2025s expectations are more tepid,yet still above the sector average,with 0.9%growth expected next year.Employment forecasts for the subsector remain positive but modest,with growth in headcount of 0.9%and 0.1%forecast across 2024 and 2025 respectively.MECHANICAL EQUIPMENTThe Mechanical Equipment subsector,a key indicator of domestic capital investment trends,faced a contractionary year as investment appetite was insufficient to see the sector grow.Output is forecast to decline by-4.6%,reflecting the aforementioned subdued investment climate.However,the outlook for 2025 is improved,with output growth of 3.3%anticipated.Employment is set to decline by-3.0%in 2024,followed by a smaller drop of-2.0%in 2025.These figures suggest that the subsector expects to grow in 2025 but with a leaner workforce on aggregate.TEXTILESThe Textiles subsector has endured negative growth projections for over three years now,with the final forecast for 2024 setting an expectation for an output contraction of-11.6%this year,the second most negative output forecast out of all subsectors this quarter.This outlook for the subsectors 2024 performance has worsened relative to last quarter where it was thought at the time the sector would shrink by-8%at the time.2025s forecast expects this contraction to soften,to-2.3%.Employment is also expected to decline acrossboth years,by-10.5%in 2024 and by a further-4.7%in 2025.This significant reduction in headcount in 2024 leaves the subsector as the most contracting this year in terms of employment.15MANUFACTURING OUTLOOK 2024 QUARTER 4Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600PAPER&PRINTINGThe Paper&Printing subsector has seen its output forecast for 2024 remain roundly consistent with the previous quarters expectations.The latest expectation is that the subsector will contract in output by-1.7%in 2024,an ever so slight improvement on last quarters forecast,but see little to no change in 2025 with growth of 0.2%forecast in the following year.The good news for the subsector and its employees is that previously forecast high levels of employment reduction have subsided from double digits to a new-3.2%,but this figure is expected to be sustained across about 2024 and 2025.ELECTRICAL EQUIPMENTThe Electrical Equipment subsector has seen its forecast for output progressively worsen throughout the year.Now,in the final quarter,the forecast for output has settled at a contraction of-6.2%for the sector.Little solace or recovery of this loss of output is expected in 2025,with a flat forecast for growth of-0.2%expected next year.Conversely,employment in the subsector is expected to grow across both years,with an expansion of 3.3%in 2024,and a further 0.9%in 2025.NON-METALLIC MINERALSThe Non-Metallic Minerals subsector is known as the subsector that supplies the construction market,providing products such as bricks,mortar,glass and other related products.This ties the subsector to the performance and appetite of the construction sector in the UK,which continues to see suppressed activity levels relative to expectations.In this quarter as it was last quarter,this subsectors output forecast for 2024 is the most contractionary out of all manufacturing subsectors and has been revised downward relative to the previous quarter.The final forecast suggests that output will decline in 2024 by-11.9%.2025 performance expectations,albeit positive,dont hold much promise to claw back lost ground,with only growth of 2.1%expected.Somewhat surprisingly,Employment is set to grow,by 3.2%in 2024 and by 0.1%in 2025.PHARMACEUTICALS The Pharmaceuticals subsector,having enjoyed sustained growth during the pandemic,is now entering a period of normalisation.Output in 2024 is expected to contract slightly by-0.5%,reflecting a return to typical demand levels.In 2025,the subsector is forecast to recover with growth of 1.9%.Employment is projected to decline by 3.2%in 2024 but return to modest growth of 0.2%in 2025.These figures suggest that while the subsector remains a vital contributor to both the sector and the wider economy,it is settling back into a post-pandemic market reality.CHEMICALSThe Chemicals subsector has received an upward revision to its 2024 output forecast in comparison to last.Previous expectations were for the subsectors growth prospects to contract by about 3%,but the latest forecasting suggests that this subsector will contract in output by a lesser-2.1%this year.2025s forecast sees a flat expectation emerge,with a contraction of only-0.17%expected next year.Employment in the subsectoris projected to remain roundly flat when averaging the coming two years.2024s forecast sees the sector grow in headcount by 1.7%,but return to contractionary territory with a figure of-2.1%in 2025.RUBBER&PLASTICSThe Rubber&Plastics subsector declined by-7.8%in output in 2023.Although negative,the subsector has not seen its forecast for output this year fall any further,despite already being moderately negative at-6.3%.Growth is forecast to return next year,however not to a commensurate degree.Output is forecast to grow by 2.4%in 2025.Employment is forecast to decline by-1.5%this year and grow by 1.3%in 2025.MOTOR VEHICLES(AUTOMOTIVE)As was the case last quarter,the Motor Vehicles subsector is the only one to be in receipt of a double-digit output growth forecast for 2024.A large driver of this growth is the remnants of catch-up activity following a multi-year production suppression arising from the pandemic and subsequent market disruptions.So,even though the forecast for growth in 2024 stands at a whopping 10%,that isnt expected to continue into 2025,where in fact a slight contraction in output of-1.1%is forecast.Employment in the subsector will see a significant decline across this year and less so in the next,with a contraction in headcount across the subsector of-5.1%in 2024 and-2.7%in 2025.OTHER TRANSPORT The Other Transport subsector which is comprised of aerospace,defence,shipping and rail industries,is set to post strong growth for the second year in a row,which becomes clear now in the final quarter of the year.Having grown in output by 6.8%in 2023,the latest forecast for this year suggests it will grow in output by a further 6%,which is an improvement in the growth forecast by a whole percentage point in only the space of one quarter.Nevertheless,this sustained high growth is not to be seen into next year as a more modest 2.8%output growth is forecast for 2025,which is still twice the scale of the sector average for 2025.Employment is forecast to grow this year,by 2.6%,but decline by a modest-0.6%in 2025.MANUFACTURING OUTLOOK 2024 QUARTER 416Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600OUTPUTEMPLOYMENT202320242025202320242025Basic metals5.2-2.2-11.5-8.5-1.5-8.3Metal products3.57.00.98.10.90.1Mechanical-3.9-4.63.3-1.2-3.0-2.0Electronics4.30.00.92.60.1-1.7Electrical0.1-6.2-0.2-0.13.30.9Motor vehicles18.910.0-1.10.6-5.1-2.7Other transport6.86.02.84.02.6-0.6Food&drink-0.22.90.8-1.7-0.2-1.5Chemicals-9.1-2.1-0.17-6.71.7-2.1Pharmaceuticals9.9-0.51.92.9-3.20.2Rubber and plastics-7.8-6.32.4-4.8-1.51.3Non-metallic minerals-10.2-11.92.1-2.53.20.1Paper and printing-5.4-1.70.2-3.1-3.2-3.2Textiles-8.7-11.6-2.3-10.6-10.5-4.7Manufacturing1.1-0.20.7-0.9-1.1-1.1Sector growth rates and forecasts%changeSource:Oxford EconomicsSource:Oxford Economics17MANUFACTURING OUTLOOK 2024 QUARTER 4Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600BDO VIEWPOINTEU CARBON BORDER ADJUSTMENT MECHANISM(CBAM)-TAXING FUTURE CARBON EMISSIONSIn order to remain competitive and maintain margins,many manufacturers have historically sourced cheaper raw materials,parts,components and also finished goods from overseas where production and labour costs are cheaper.Whilst this can lower the cost of manufacturing and procurement,it often comes with higher carbon emissions which is becoming an increasing environmental concern as the ESG agenda heats up.The UK and EU governments growing focus on the need to meet their net zero targets for carbon emissions domestically could,paradoxically,be adding to the problem.Importing cheaper goods often from countries that have not imposed tougher emissions standards could,in turn,result in exporting carbon emissions.Carbon leakage caused by importing high-emission products is a well-established problem and needs to be addressed if net zero targets are to be achieved.WHAT IS CBAM?The Carbon Border Adjustment Mechanism is a piece of EU legislation which affects UK exporters.From 1 October 2023,the EU introduced rules to ensure that CO2 emissions created in the manufacture of goods imported into the EU are recorded and reported.Although reporting requirements for the CBAM have been implemented,it wont be until 2026 that businesses will have direct costs under the scheme.Businesses will then have to purchase certificates under the EU Emissions Trading Scheme to cover the imports of such goods,effectively increasing their price and taxing the related emissions.UK businesses exporting to the EU will be affected first,with the administrative reporting burden starting this year and either needing to provide this data to the EU importer or doing so themselves if they import directly.This will include appointing an EU-based reporting agent if the UK business has no establishment in the EU.UK CBAM PROPOSALSFollowing a consultation this year by the UK government to address future carbon leakage,they announced their approach to CBAM late October.UK CBAM will be introduced in January 2027,several years after the EUs regime and a year after the EU regime creates costs for importers.UK CBAM will cover the aluminium,cement,fertilizer,hydrogen and iron and steel industries.The ceramics and glass industry will be included at a later point in time.The regime will cover both direct(manufacturing emissions)and indirect emissions(those relating to the amount of electricity consumed in the production process)of CO2,with Perfluorocarbon PFS for the aluminium industry and NO2 Nitrous Oxide for the fertilizer industry also included.CBAM rates for each covered good will be set and updated quarterly.Actual emissions will need to be reported but there will be a facility to use default values if they are not available to importers.UK importers will pay the difference between the UK set carbon price minus any carbon price paid in the country of manufacture.Whilst the EU CBAM regime covers shipments greater than 150,the UK CBAM regime will cover imported goods that total over 50,000 in a rolling 12-month period.This means monitoring your imports will be essential for compliance.HOW TO PREPARE?UK manufacturers should already be monitoring their exports to the EU and assisting their EU customers or reporting CBAM goods in their own name.Understanding the UK CBAM regime,affected products and the level of embedded emissions in goods currently imported into the UK by manufacturers should begin now.Ascertaining the carbon profile of your suppliers in advance is essential,as transitioning to other suppliers with better carbon profiles could take considerable time.BDOs Customs Data Analytics Tool simplifies the process of analysing Management Support System data from HMRC to help you reduce the risk of customs duty assessments and civil penalties.Book your free demo here:https:/store.bdo.co.uk/product/customs-data-analytics-toolMatthew ClarkPartner/Customs,Excise and International Trade Servicesmatthew.clarkbdo.co.ukMANUFACTURING OUTLOOK 2024 QUARTER 418Job No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Accountancy and business advisory firm BDO LLP is the UK member firm of BDO International,which has more than 1,700 offices in 166 countries.We operate from 17 offices across the UK,employing 7,500 people offering tax,audit and assurance,and a range of advisory services.Manufacturing is a priority sector for BDO and this focus enables us to tailor the wide range of services we offer and apply our skills and knowledge to help clients achieve their objectives.We provide real solutions to industry issues,utilising our capabilities in everything from sector-specific accountancy,tax and business advice to patent box and research and development claims and M&A opportunities to help our clients grow in the UK and overseas.We also provide manufacturing businesses and organisations with robust,independent audits.We have an excellent understanding of the issues affecting UK manufacturers as an industry sector,but we also focus on specific sub-sectors to improve our knowledge and our service to clients.These include:advanced manufacturing,aerospace,automotive,building products,chemicals and pharmaceuticals,food and drink,electronics,industrials,test and measurement and technology.Manufacturing remains one of the key industries of the UK economy.We are delighted to be able to play an active role in supporting the businesses that operate in this vibrant,changing and challenging sector.For further information about our business and services,please visit our website:www.bdo.co.uk Make UK,The Manufacturers Organisation,is the representative voice of UK manufacturing,with offices in London,every English region and Wales.Collectively we represent 20,000 companies of all sizes,from start-ups to multinationals,across engineering,manufacturing,technology and the wider industrial sector.Everything we do from providing essential business support and training to championing manufacturing industry in the UK and internationally is designed to help British manufacturers compete,innovate and grow.From HR and employment law,health and safety to environmental and productivity improvement,our advice,expertise and influence enables businesses to remain safe,compliant and future-focused.MakeUK.orgTo find out more about this report,contact:Fhaheen KhanSenior EconomistfkhanMakeuk.orgJames BroughamSenior EconomistjbroughamMakeuk.orgSeamus NevinChief EconomistsnevinMakeuk.orgMake UK Information Line0808 168 5874researchMakeuk.orgThe data used in this survey have been provided by UK manufacturers including members of Scottish Engineering,Manufacturing NI,and Make UK.Contributing to our surveys helps to accurately reflect trends and behaviours that shape the UK manufacturing sector.If you would like to participate in future surveys,please contact our Information and Research team researchMakeuk.orgTo talk about any issues your manufacturing business may be facing please contact:Richard AustinHead of Manufacturing,BDO LLP07808 24613richard.austinbdo.co.ukBaljit BhamraMarketing and Business Development Manager,BDO LLP0121 352 6296baljit.bhamrabdo.co.ukIDEAS|PEOPLE|TRUSTJob No:53857Proof Event:3Park Communications LtdAlpine WayLondon E6 6LACustomer:MakeUKProject Title:Manufacturing Outlook 2024 Q4T:0207 055 6500F:020 7055 6600Make UK is a trading name of EEF Limited.Registered Office:Broadway House,Tothill Street,London,SW1H 9NQ.Registered in England and Wales No.05950172PROCESS INNOVATION:BRINGING MANUFACTURERS TO THE FRONTIERMake UK champions and celebrates British manufacturing and manufacturers.We stimulate success for manufacturing businesses,allowing them to meet their objectives and goals.We empower individuals and we inspire the next generation.Together,we build a platform for the evolution of UK manufacturing.We are the catalyst for the evolution of UK manufacturing.We enable manufacturers to connect,share and solve problems together.We do this through regional and national meetings,groups,events and advisory boards.We are determined to create the most supportive environment for UK manufacturers to thrive,innovate and compete.We provide our members with a voice,presenting the issues that are most important,and working hard to ensure UK Manufacturing performs and grows,now and for the future.To find out more about this report,contact:Name SurnameJob Titleemailmakeuk.orgName SurnameJob Titleemailmakeuk.orgName SurnameJob Titleemailmakeuk.orgQueens Park Queens Way North Team Valley Trading Estate GatesheadTyne and Wear NE11 0NXt:0191 497 3240e:enquiriesmakeuk.orgmakeuk.orgMake Business is a trading name of EEF Ltd,an employers association regulated under part II of the Trade Union and Labour Relations(Consolidation)Act 1992.EEF Limited.Registered Office.Broadway House,Tothill Street,London,SW1H 9NQ.Registered in England and Wales.No.05950172.makeuk.org(C)2024 Make UKFK.JB.16.12.24
2025-01-06
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Global Valve and Actuator Market Outlook Autumn 2024 Sample material Copyright 2024 Oxford Economic.
2024-12-31
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5星级
Industry Multiples in Latin AmericaNinth EditionQ4 2024Table of Contents2Page1.Foreword32.Summary53.
2024-12-30
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