Disproved: 7 Concerns About Digital Manufacturing
Success stories in smart production: How companies have gained measurable competitive advantages by digitizing production
Digital manufacturing, MES software, and the digitization of production are key success factors for the IIoT. They help companies optimize their manufacturing processes, reduce costs, and ensure competitiveness, especially for small and medium-sized enterprises.
Nevertheless, many companies still have persistent reservations about smart manufacturing. In this article, we have compiled seven of these typical concerns – and disproved them with real case studies and proven successes.
1. Concern: “Our machines are too old and too different for digital connectivity.”
Disproved: With modern MES software and suitable connectivity solutions, even older machines can be integrated into digital manufacturing.
Practical example: LOEW Präzisionsteile GmbH (Germany)
This German Nuremberg-based company is a certified, reliable, and competent partner for all aspects of precision parts and machining. The company has been manufacturing sophisticated high-tech components for 30 years.
With 50 highly qualified employees, LOEW specializes in the manufacture of complex components from a wide variety of materials and their finishing. Its customers come from a wide range of industries, primarily medical technology, aerospace, defense, and optics.
The precision parts manufacturer has digitally connected all its machines, regardless of their year of manufacture. Complete data integration has been achieved with the help of I/O controllers and the MES FLEX solution from FORCAM ENISCO.
The result: complete transparency across all connected manufacturing processes.
2. Concern: “Introducing digital manufacturing disrupts ongoing production.”
DISPROVED: A smart, step-by-step implementation plan protects ongoing production and delivers immediate, measurable value.
Practical example: BWF Group (Germany)
The company in Bavaria is an international technology leader in the fields of industrial filters, wool felt, technical needle felt, and plastic profiles. With over 125 years of experience and a global presence, the BWF Group combines tradition, innovative strength, and the highest quality standards.
Back in 2018, the company established its own department for innovation and digitalization, “Innotec by BWF Group.” Since then, digitalization has been systematically advanced in targeted steps.
Today, the company benefits from transparency through real-time data in production, alerts on mobile devices, automated energy data collection, and compliance with reporting requirements—all without interrupting production.
3. Concern: “Digital manufacturing costs more than it benefits.”
DISPROVED: A return on investment (ROI) can be achieved after just a few months if the process and technology are chosen wisely. Measurable success also increases motivation.
Practical example: MPS Micro Precision Systems AG (Switzerland)
Founded in 1936, MPS Micro Precision Systems AG produces micromechanical solutions for industries with the highest demands – medical technology, the watch industry, and aerospace.
Raynald Richard, Manager of Information Systems at MPS AG: “As a supplier of precision systems, we set the highest standards in manufacturing. FORCAM’s MES solution offers us a flexible tool with a seamless real-time connection to SAP/ERP.”
With MES FLEX, MPS was able to double the utilization of its workstations – without additional machines.
The enormous benefit: production output equivalent to a second factory – without the corresponding construction costs.
4. Concern: “Smart manufacturing is only for statistics enthusiasts.”
DISPROVED: Added value is created when data from digital manufacturing is strategically analyzed and used to optimize production.
Practical example: Foundation Wellness (USA)
Foundation Wellness is a leading US company in the fields of pain relief, prevention, and general well-being.
Before introducing a manufacturing execution system (MES), Foundation Wellness relied on manual processes for data collection in production. This led to a lack of transparency and hindered rapid problem solving and strategic decision-making.
After introducing the MES FLEX solution and a culture of continuous learning, the company increased its overall equipment effectiveness (OEE) from 77% to almost 85%. This is a prime example of successful data-driven manufacturing.
5. Concern: “Digital manufacturing is not worthwhile in high-wage countries.”
DISPROVED: With a modern management culture and a modern MES software solution, productivity can be increased and manufacturing kept in the home country.
Practical example: peka-metall AG (Switzerland)
Peka is a leading manufacturer of pull-out systems and complete interior fittings for the kitchen and furniture industry, based in Mosen, Switzerland.
The company reduced the effort required for product approvals by up to 50% and measurably improved planning quality – clear evidence that digitizing production makes a significant contribution to remaining competitive, even in a high-wage country.
6. Concern: “Smart manufacturing solutions are not compatible with our systems.”
DISPROVED: Open and modular solutions enable smooth integration into existing IT landscapes.
Practical example: NMH GmbH (Germany)
NMH is a “hidden champion” for complex measuring, testing, and assembly systems.
With the support of FORCAM ENISCO software, heterogeneous machines could be seamlessly connected—with 30% more system availability—without replacing the existing shop floor software.
7. Concern: “Employees are not on board.”
DISPROVED: Acceptance comes through training, communication, and visible benefits.
With a motivated workforce and powerful MES software, digital manufacturing is a clear competitive advantage.
With the right partner and future-proof MES software, digital manufacturing is not a risk, but an opportunity to improve manufacturing processes, reduce production costs, and ensure competitiveness.
Success factors:
- Clear roadmap
- Pilot projects
- Communication with the workforce
- Continuous optimization of manufacturing processes
Best practices:
- LOEW: A change team and a clearly designated project manager (“transformer”) were key success factors.
- BWF Group: Training at all levels led to high motivation.
- Foundation Wellness: Successful implementation through communication in small steps and leadership with a sense of proportion.
- peka-metall AG: Employees praise the new transparency and opportunities for improvement.
Want to learn more? We look forward to hearing from you!
customerrelations@forcam-enisco.net
