Built for speed: Supercharge your shop floor with digital transformation

The manufacturing sector is undergoing a rapid digital transformation. According to the International Data Corporation (IDC), global spending on digital transformation is projected to rise to nearly $4 trillion by 2027. Several key factors are advancing this change. For starters, customers expect tight tolerances and faster turnaround times, which are challenging to achieve with traditional workflows. External pressures also play a role. Global supply chain disruptions, driven by trade wars and geopolitical tensions, have made businesses across the globe rethink their strategies to crisis-proof their operations. Additionally, there is increasing pressure to meet sustainability targets to lower environmental impact.

For most manufacturers, digital transformation is no longer optional –it is becoming essential for long-term survival and competitiveness. Embracing smart manufacturing technologies enables businesses to streamline operations, improve part quality, and respond more quickly to market demands. However, as a McKinsey study highlights, 70 percent of transformations fail. This is why the expertise of industry leaders such as Hexagon are pivotal in digital transformation. This article provides a wireframe for an effective digital transformation of manufacturing facilities.

Hexagon’s Blueprint for Shop Floor Excellence

The traditional siloed model, where design, production, and quality control operate in isolation is quickly becoming outdated. Disjointed workflows lead to delays, errors, and inefficiencies. Hexagon's smart manufacturing solutions offer a blueprint to transition from fragmented workflows, to digitally connected ecosystems. With an approach based on automation, integration, and insight, Hexagon can help streamline operations, reduce variability, and deliver real-time intelligence to support better decision-making.

Automation

Repetitive manual tasks not only waste time but also hold up skilled labor. Automating routine processes such as part inspection not only speeds up processes, but also reduces the risk of human error.

One way to achieve this is by integrating coordinate measuring machines (CMMs), robotic arms, and inline inspection systems into a fully automated workflow. For example, Skoda leveraged Hexagon's laser scanning and automation platform to cut inspection time for parts and sub-assemblies by nearly 50%. This not only accelerated throughput, but also ensured greater measurement repeatability and consistency across the production line. By automating inspection and feedback loops, manufacturers can achieve a closed-loop quality control system.

Integration

In traditional manufacturing, systems operate independently and create data silos that limit visibility. This leads to disconnected and disparate systems that require manual intervention, which costs shop floor operators valuable time and money.

To overcome this, a digital thread that ensures data flows effortlessly across all stages of the manufacturing process is crucial. Digital platforms such as the Nexus cloud platform enable collaboration by connecting employees, technologies, and data across design, production, and inspection. It breaks down information silos and facilitates real-time collaboration and feedback between different teams and departments.

This level of connectivity helps reduce delays and miscommunication while enhancing traceability. It is especially critical for industries with strict regulatory requirements or where high precision is non-negotiable.

Insight

Collecting data is just the first step. To stay competitive, manufacturers need to make sense of that data and turn it into action. With real-time analytics and AI-powered tools, Hexagon provides manufacturers the insight they need to make data-driven decisions. According to the company’s Advanced Manufacturing Report survey, 76% respondents believe that investing in enhanced data sharing and collaboration between teams will improve product quality.

Solutions such as SPC (Statistical Process Control) software allow companies to monitor quality metrics in real time, identify trends, and implement corrective actions before it is too late. Furthermore, the use of digital twins adds another layer of intelligence. These virtual models simulate production scenarios, predict outcomes, and help optimise performance without interrupting actual operations. With these tools, decision-makers gain the visibility needed for proactive management.

Seven-step roadmap to drive digital transformation

Digital transformation touches upon every stage of the manufacturing lifecycle. The goal is to eliminate inefficiencies, improve collaboration, and deliver quality from initial quoting to final reporting. This framework provides practical steps to drive measurable improvements in efficiency, quality, and profitability.

1. Quoting and planning

In manufacturing, detailed and accurate quotes are essential. By integrating automation and AI-powered tools, manufacturers can generate precise quotes in a fraction of the time compared to manual methods. Use of historical data and advanced algorithms can ensure consistency in quoting practices.

2. Designs and reviews

Digital transformation allows manufacturers to cater to diverse design needs and accommodate new requirements. Real-time design reviews between engineering and customers streamline feedback loops, which minimise rework by ensuring accuracy. This flexibility is key to delivering customised solutions at speed.

3. Manufacturing preparation

Manufacturing preparation sets the tone for production success by ensuring smooth handovers from design to shop floor. This includes collision-free code creation, fixture preparation, and integrating additive manufacturing and digital simulation for increased efficiency. As a result, it reduces manual errors, improves accuracy, and accelerates readiness.

4. Manufacturing

By connecting advanced machine tools with IoT sensors and real-time monitoring systems, manufacturers gain real time visibility into their shop floor operations. When combined with automation, machine learning, and AI, these insights help optimise workflows, reduce downtime, and ensure consistent quality across batches.

5. Shop-floor measurement

Precision plays a crucial role in manufacturing.  To maintain it, advanced measurement technologies should be embedded into the production floor. By capturing real-time data, these tools help identify issues early, deliver actionable insights, and support continuous process improvements. This ensures that every part meets design intent and quality standards.

6. Inspection

Inspection is critical for quality checks and retaining customer trust. Using technologies such as coordinate measuring machines (CMMs) and 3D laser scanners, manufacturers can validate part accuracy with exceptional precision. These detailed measurements not only confirm that components meet specifications but also provide insights for root-cause analysis.

7. Reporting

Robust reporting systems are pivotal in creating a feedback loop for continuous improvement in the production facility. By systematically capturing measurement and quality data, engineers can trace issues back to their source. This data-driven visibility supports root-cause analysis, drives process optimisation, and enables iterative improvements across the production cycle.

Case Study: Hexagon’s Integrated Solutions in Action

To demonstrate the impact of Hexagon’s solutions, let’s take a look at an anonymised customer success story that shows how the company improved production quality and efficiency across the production cycle.

Challenge

An established machining business, Precision Machineworks, faced several operational inefficiencies and competitive pressures as drawn out below:

• Manual workflows that limited scalability and introduced human error

• Frequent machine breakdowns that disrupted production timelines

• Poor visibility into manufacturing operations

• Difficulty adapting quickly to customer design modifications

• Skill gaps in handling new technologies

• Siloed departments that limited collaboration

These challenges put Precision Machineworks at risk of falling behind in an increasingly digital and customer-driven market.

Solution

To address these concerns, Precision Machineworks undertook a digital transformation journey through Hexagon’s smart manufacturing solutions. Their approach included:

• Deployment of CNC machines integrated with IoT sensors that enabled real-time monitoring

• Establishment of a centralised data system accessible to both engineers and operators for informed decision-making

• Employee training programs designed to upskill the workforce in connected technologies, data analytics, and advanced troubleshooting

• Promotion of cross-functional collaboration to identify improvement areas

Result

The implementation of Hexagon’s solutions resulted in measurable improvements across the company's production cycle:

• Significant reduction in machine downtime due to predictive maintenance capabilities

• Increased throughput and operational efficiency from streamlined workflows and smarter scheduling

• Enhanced resource management and faster decision-making driven by real-time data access

• Improved customer satisfaction through consistent product quality and quicker adaptation to last-minute design changes

Conclusion

Digital transformation starts with the right strategy and the right partner. As manufacturers face increasing pressure, embracing smart manufacturing is no longer optional, but essential. However, this shift requires more than just new tools. You need a trusted partner who understands the challenges of this transformation.

Hexagon provides the tools and expertise to modernise your production facility. Through automation, integrated systems, and data analytics, Hexagon’s solutions help manufacturers bridge silos and boost collaboration. As demonstrated in the case of Precision Machineworks, a well-executed digital transformation can reduce downtime, enhance decision-making, and drive long-term competitiveness.

Begin your manufacturing facility transformation with Hexagon. Download the playbook to unlock your shop floor potential.