How Connected Manufacturing Is Transforming the Industry

Ken Fisher

The rise of Industry 4.0 has accelerated the need for smarter and more streamlined manufacturing operations. As manufacturing companies strive to innovate and adapt in this rapidly evolving technological landscape, connected manufacturing has emerged as a crucial element of success. This core component of Industry 4.0 is revolutionizing the industry, offering numerous benefits to businesses across the globe.

In this discussion, we’ll explore the origins of connected manufacturing, the driving forces behind its adoption and its transformative effects on the manufacturing sector. Understanding these aspects makes it easier to grasp the significant role connected manufacturing plays in Industry 4.0 and its impact on the future.

What Is Connected Manufacturing?

Connected manufacturing is an innovative approach focusing on streamlining and optimizing manufacturing processes using advanced technology. It encompasses the following key features:

  • Harnessing cloud computing: This technology enables businesses to collect, store and analyze vast amounts of operational and business data. This enables better decision-making and continuous process improvement.
  • Enhancing connectivity: Connected manufacturing strengthens the links between connected workers, machinery and supply chains. This increased connectivity facilitates seamless communication, real-time monitoring and coordination across various operations.
  • Boosting efficiency and control: By providing end-to-end visibility into manufacturing processes, connected manufacturing helps businesses to identify bottlenecks, optimize resources and enhance overall productivity.
  • Improving customer satisfaction: With better insights into processes and a more agile manufacturing setup, businesses can deliver higher-quality products and services, leading to increased customer satisfaction.

A connected factory is a manufacturing facility that embodies the principles of connected manufacturing. It incorporates the following elements:

  • Sensors and data collection: Connected factories are equipped with sensors that continuously collect data from manufacturing equipment and processes. This data can include machine performance, product quality and energy consumption information.
  • Cloud-based storage and analytics: Data collected by sensors is stored and processed in the cloud, which offers cost-effective and scalable solutions for managing vast amounts of information.
  • Real-time insights and decision-making: Connected factories utilize advanced analytics to process historical and real-time data, generating valuable insights that inform decision-making and drive continuous improvement.
  • Integration of technologies: A connected factory seamlessly integrates various technologies, such as the Industrial Internet of Things (IIoT), big data analytics, artificial intelligence (AI) and cloud computing, to create a cohesive and intelligent manufacturing environment.

What a Connected Factory Looks Like

A connected factory is a modern manufacturing facility that seamlessly integrates advanced technologies to optimize operations, increase agility and reduce risks. Here’s a glimpse of a hypothetical connected factory in action and the various technologies involved:


  • IIoT: A connected factory employs a network of smart devices, sensors and machines to collect and exchange data in real time, driving innovation in manufacturing processes.
  • AI and machine learning: These technologies enable predictive maintenance, quality control and automation, leading to increased innovation in product development and production techniques.


  • Cloud computing: By leveraging cloud-based solutions, connected factories can quickly adapt to changes in demand, scale operations up or down and access data from anywhere at any time.
  • Digital twins: These virtual representations of physical assets and processes allow manufacturers to test and optimize production strategies, enabling them to respond quickly to changing market conditions.


  • Advanced data analytics: Connected factories use advanced analytics to process and analyze data from various sources, driving informed decision-making and continuous process improvements.
  • Robotics and automation: Integrating robots and automated systems in connected factories helps streamline operations, improve accuracy and reduce human intervention, increasing efficiency and cost savings.


  • Cybersecurity: Connected factories prioritize robust cybersecurity measures to protect sensitive data, intellectual property and production systems from external threats.
  • Real-time monitoring: By continuously tracking and analyzing data from machines, equipment and processes, connected factories can identify and proactively mitigate potential risks.

These key components work together to ensure a future-proof, responsive and optimized manufacturing operation.

Key Drivers Behind Industrial Digitalization

The rise of connected manufacturing and Industry 4.0 can be attributed to several key business drivers that offer significant benefits to manufacturers. These drivers include:

  • Cost optimization: Connected manufacturing reduces operational costs by streamlining processes, improving resource utilization and enabling predictive maintenance, which minimizes downtime and extends the life of machinery.
  • Increased productivity: By integrating advanced technologies such as AI, robotics and automation, connected manufacturing increases overall productivity by reducing manual tasks and human errors and enhancing the efficiency of production processes.
  • Opportunities for new revenue streams: Connected manufacturing enables manufacturers to create new revenue streams by offering value-added services, such as predictive maintenance, data-driven insights and customized products that cater to evolving customer needs.
  • Process efficiencies: Real-time data monitoring and advanced analytics provide manufacturers with actionable insights that lead to more efficient processes, waste reduction and energy savings, resulting in a more sustainable and cost-effective operation.
  • Improved customer experiences: Enhanced visibility and control over the manufacturing process allow businesses to deliver higher-quality products and services, thereby boosting customer satisfaction, loyalty and long-term relationships.
  • Stronger competitive standing: Adopting connected manufacturing and Industry 4.0 technologies helps manufacturers stay ahead of the competition by embracing innovation, increasing agility and leveraging the power of data to make better, more informed decisions.

How to Create a Connected Factory

Creating a connected factory requires a strategic approach that encompasses several key steps. Here are some recommendations:

  1. Break down silos & increase cross-departmental collaboration: Encourage open communication and collaboration between different departments to foster a culture of innovation, knowledge sharing and efficient decision-making that will contribute to a more cohesive and connected manufacturing environment.
  2. Visualize the customer journey through journey mapping: By mapping out the customer journey, manufacturers can gain a deeper understanding of customer needs, preferences and pain points, enabling them to optimize their production processes and product offerings to better serve their customers.
  3. Consider adopting a new business model & shift to an As-a-Service offering: Embrace a new business model, such as offering manufacturing services on-demand, to create new revenue streams, increase flexibility and adapt to the changing needs of customers and the market.
  4. Upgrade or replace legacy systems: Outdated systems can hinder the implementation of connected manufacturing technologies. Replace or upgrade legacy systems with modern solutions that can seamlessly integrate with advanced technologies like IIoT, AI and cloud computing.
  5. Invest in the right technology: Equip your factory with the right mix of technologies, such as industrial IoT, big data analytics, AI, cloud computing and mobile collaboration and productivity solutions. These technologies enable real-time monitoring, data-driven decision-making and process optimization, ultimately transforming your facility into a connected factory.

Connected manufacturing is transforming the industry, enabling businesses to optimize operations, improve customer experiences and maintain a competitive edge in an increasingly digital world. Creating a connected factory requires strategic planning, investment in the right technologies and a commitment to embracing innovation.

With Redzone’s connected workforce management solutions, manufacturers can successfully navigate the challenges and opportunities presented by connected manufacturing and Industry 4.0. Discover how you can unlock the full potential of your manufacturing operations with Redzone. Book a demo today to learn more.

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Ken Fisher Ken Fisher, the SVP of Product Management and Solutions Consulting at Redzone, is a seasoned professional with over 20 years of experience in manufacturing operations and lean transformation. He has a deep understanding of industry challenges and is dedicated to recognizing the value of frontline workers in manufacturers' success. Ken leads a team at Redzone that enhances current products, develops new solutions, and works with factories to design digital production systems that achieve operational goals. He also served as a Continuous Improvement Coach, implementing Redzone in food processing facilities. Notably, Ken spoke at the Food Safety Summit in 2019. He holds a B.S. in Industrial Engineering from the University of South Florida and an M.B.A. from the University of Florida.

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