Embracing AI-powered operations: A maturity path for manufacturers
Manufacturers today are feeling pressure from multiple angles. Customers expect custom products delivered faster than ever, global supply chains remain unpredictable, and every decision counts with tariff questions looming. In this environment, making smarter decisions with real-time data and AI is essential to stay ahead.
Leading this shift are what Microsoft calls “Frontier Firms.” These companies change how they work to get the most out of AI. They run on on-demand intelligence and rely on hybrid teams where people and AI agents work side by side. They move fast, scale quickly, and deliver value sooner. In these companies, AI tools grow from simple assistants into trusted digital colleagues. These firms are ready to reinvent workflows and entire business models for the AI era. They are not just using technology; they are transforming how they operate, make decisions, and innovate.
A clearer path forward
Many manufacturers are still working through basics like old equipment, scattered data, manual processes, and not enough skilled workers. That is where a clear roadmap can make all the difference.
This is why we worked with IDC to create The Maturity Path for Manufacturers to Embrace AI Enabled Operations. It is a short assessment that gives you a custom report and benchmark, showing where you are today and what steps to take next.
Real stories, real results
We are seeing transformational efforts from customers evolving with AI:
- Sandvik is rethinking how it makes products with Microsoft AI.
- Textron Aviation is using Microsoft Azure AI solutions to make aircraft maintenance faster and smarter.
- Husqvarna Group is boosting efficiency with Microsoft Azure Adaptive Cloud and is already putting generative AI on the factory floor.
Our partners are helping too. Siemens is working with Microsoft to help manufacturers automate and scale AI across industries and Sight Machine is putting agentic AI on the plant floor—giving operators real time help to solve problems and make better decisions.
What gets in the way
For most manufacturers, a few challenges keep coming up:
- Data stuck in silos or old systems.
- Manual workflows that cannot keep up with demand.
- Security gaps as factories connect more machines to IT systems and the cloud.
- A shortage of workers with digital skills.
- Growing complexity as product lines expand and change faster than ever.
These challenges do not solve themselves, Frontier Firms face them head on. They break down data silos, modernize infrastructure, strengthen security, upskill people, and make data easy to use every day.
How the maturity model works
IDC’s five stage MaturityScape for Data Driven Operations shows how to move forward step by step. Progress happens across three areas at the same time: data, technology, and people.
- Data: Good AI starts with clean, reliable, and well-organized data. Many manufacturers still need to break down silos and build a single source of truth. A cloud platform helps keep everything connected, secure, and ready for AI.
- Technology: Once the data is in place, it is time to digitize, connect, and automate. Smart companies pick use cases that make sense—like predictive maintenance or quality checks—and build from there. Security must be part of every step.
- People and process: The best technology does not matter without people ready to use it well. Leaders need to champion the shift, connect IT and operations, and build teams that mix data scientists with factory experts. Workers need the skills and tools to make faster, better decisions with AI at their side.
Getting from pilot to full scale
A lot of manufacturers run pilots but get stuck. Frontier Firms keep moving. They have a clear roadmap, celebrate quick wins, and stay focused on the bigger picture. They share what they learn, expand infrastructure, and build skills in house. Many set up a center of excellence to keep things on track and executive support and clear measures keep the momentum going.
IDC predicts that by next year nearly half of manufacturers will be using AI at scale, unlocking up to a 5% boost in profit or revenue. For those reaching the highest maturity levels, AI agents will not just assist, they will work alongside people as trusted digital colleagues—changing how factories run every day.1
Where to start
Get your data in shape. Take stock of what you have, fix the gaps, and build data skills across teams. Pick a simple pilot with clear value and secure leadership support early.
Build on it. Expand how you collect and centralize data. Put governance in place, add more analytics tools, set up teams focused on digital transformation, and share early wins.
Scale and standardize. Use the cloud when it makes sense. Standardize tools and platforms, and make sure teams are truly cross functional and that decision making is faster and backed by real data.
Keep going. Even at higher stages of maturity, keep sharing data with partners when appropriate, test new technology, and keep AI models governed responsibly.
Where we are headed
The future of manufacturing is smart, connected, and powered by AI. The companies that lead will be those that work like Frontier Firms. They will treat AI as part of how they operate, not just a bolt on. They will pair people with AI agents that become trusted digital teammates and they will keep looking for new ways to reinvent what is possible.
At Microsoft, we are here to help. Our work with leaders like Sandvik, Textron, Husqvarna, Siemens, and Sight Machine shows what happens when manufacturers commit to the journey. You can start today, no matter where you are now.
Each step moves you closer to what Frontier Firms already see, including faster decisions, stronger resilience, and a business ready for what comes next.
Take the assessment and see where your journey begins.
Find your organization’s path to advancing its industrial AI transformation
Benchmark your digital maturity across key dimensions of success
1 IDC FutureScape: Worldwide Manufacturing 2023 Predictions.
