Rockwell Automation and CAR Join Forces on a New White Paper

Is the automotive industry finally moving beyond the "pilot purgatory" of smart manufacturing? And if so, what does the next phase actually look like—not in theory, but on the factory floor?

Rockwell Automation and the Center for Automotive Research (CAR) have teamed up to release a white paper that takes a hard look at exactly those questions. Titled Smart Manufacturing in Automotive: Deployment and Impact, the report draws on proprietary data from Rockwell Automation’s 11th annual State of Smart Manufacturing study, combined with CAR’s independent industry analysis. The answer they arrive at is clear: the industry is entering a new phase of adoption, and the debate is no longer about whether to invest, but how quickly—and where to apply the technology first.

Beyond the Low-Hanging Fruit

For years, automakers and suppliers have leaned heavily on advanced automation in body shops, paint lines, and welding cells. Those were the easy wins. But the white paper suggests the frontier is shifting into territory that has historically been much harder to automate: electronics assembly, validation testing, production coordination, and logistics. At the same time, AI and machine learning are no longer experimental add-ons—they are being woven into predictive maintenance, inspection accuracy, and overall system performance across existing operations.

"Manufacturers are being asked to do more with less while managing greater complexity," said James Glasson, VP of Global Industry – Automotive, Tire & Advanced Mobility at Rockwell Automation. "The combination of automation and AI is helping teams identify issues earlier, reduce downtime and improve performance across plants. The difference now is how effectively companies scale these capabilities".

The Numbers That Matter

What does "scaling" actually deliver? The findings cite measurable results that should grab any production manager's attention: up to 50% reductions in unplanned downtime in select applications, roughly 5% improvements in overall equipment effectiveness (OEE), and 5% to 7% gains in throughput from real-time production analytics. Those aren't incremental tweaks—they are competitive differentiators.

A Growing Divide

Perhaps the most thought-provoking finding, however, is the widening gap across the industry. The white paper points to a growing divergence in adoption rates, creating tangible differences in quality, uptime, and productivity—with direct implications for supplier performance and long-term competitiveness. In other words, the gap between the leaders and the laggards isn't just about technology; it's about market position.

So what's driving this urgency? The report identifies several pressure points: increasingly complex production environments, ongoing warranty pressures, rising costs, and intensifying global competition. There's also a geopolitical dimension—automation is helping enable onshoring by supporting cost-competitive production even in tight labor markets.

Why This Paper Matters Now

Edgar Faler, principal mobility analyst and strategy lead at CAR, put it succinctly: "The industry has built a strong automation foundation. What is changing now is how manufacturers are using AI and data to manage growing complexity, improve decision-making, and create competitive advantage. Those that move faster are starting to see measurable advantages".

The full white paper is now available, and it arrives at a pivotal moment. As automotive manufacturers navigate electrification, supply chain upheaval, and shifting consumer expectations, the question is no longer whether smart manufacturing will define the next decade—it's whether your organization will be leading the charge, or playing catch-up.