Did you know that manufacturers are still using paper in more than a third (35%) of their processes on average? What’s more, manual spreadsheets are still used for nearly half (49%) of all manufacturing-related processes. In fact, the use of technology (or lack of) – where only 37% manufacturers are effectively leveraging current technology – was cited as the biggest barrier to productivity, ahead of processes (32%) and people (31%). This was according to figures published by iBASEt in May 2022 in the Manufacturing Digital Productivity Report.
The report above involved 403 highly engineered industrial manufacturers from both the US and UK, revealing that the industry’s biggest productivity hamper is a reluctance to embrace digital tools and technologies. More UK respondents compared to their US counterparts said that legacy technologies have had a far more negative impact on their business (73%) compared to Brexit (67%).
The report also revealed that 56% of UK manufacturers are not hitting their sales targets as a result and 93% say that technological underinvestment may lead them to go out of business within a decade or so.
The key findings of the report point to one thing: manufacturers’ reluctance to let go of legacy processes and systems. Since 83% of manufacturers said their business was adversely impacted by the pandemic in the past 18 months, at least 67% of them adopted Industry 4.0 and smart factory technologies to survive amid the social distancing guidelines. As a result, 68% claimed it made them more productive while 51% said it led to better business agility.
Unfortunately, 56% of UK manufacturers are still not harnessing the power of Industry 4.0 with 19% not using any of the data whatsoever.
The problem (again) mostly lies in a general lack of digital maturity – an insistence on running operations through pen and paper or spreadsheets. This is leading to higher production and process-related errors, with the overall manufacturing process slowing down a great deal. The end result is an acute difficulty in attracting the new generation of manufacturing workforce.
If you think about it, all this adds up to not only a drop in company performance, but also a loss of trade, and ultimately, leadership positions coming under threat.
Now is the time for every UK manufacturer to take action and embrace the digital revolution. And, this is not a matter of “if” but a matter of “sooner rather than later”.
As part of their digital maturity strategy, every manufacturing business must adopt the latest tools and technologies to stay ahead of the competitive curve and beat economic woes.
The next generation of talent is going to rely heavily on technology so pen and paper or traditional spreadsheets will simply not cut it anymore.
For more information about moving to a paperless reporting process.
As AMRs (Autonomous Mobile Robots) become standard in UK warehouses, managing Human-Machine Collaboration (HMC) is the new safety frontier. Success requires a "Connected Worker" strategy involving dynamic geofencing and unified traffic dashboards. In 2026, HSE inspectors look for integrated digital systems that protect workers in shared spaces without compromising the efficiency of robotic automation.
Mental health is now a core priority for HSE inspections in the UK manufacturing sector. Under the Management of Health and Safety at Work Regulations 1999, employers must conduct formal Psychosocial Risk Assessments. Moving beyond "open door policies" to documented digital workflows ensures that stress, workload, and burnout are quantified and managed with the same rigour as physical hazards.
In 2026, UK warehouse safety is shifting from reactive reporting to Predictive Safety Workflows. By integrating AI with computer vision and wearable sensors, H&S Managers can identify "near-miss" patterns before collisions occur. This data-driven approach reduces RIDDOR-reportable incidents by up to 30%, providing the "Golden Thread" of evidence required for modern HSE duty of care compliance
Without a structured system, multi-site safety quickly becomes inconsistent, reactive, and difficult to defend during audits. That’s why organisations with distributed operations are adopting multi-site inspection software to regain control, enforce standards, and maintain compliance from one central platform.
In 2025, leading organisations are using safety audit data analytics to move beyond reactive reporting turning everyday inspections into early-warning systems that prevent incidents before they happen.
Safety audits, inspections, maintenance, and reporting all need to work together yet in many organisations, inspection data still sits in silos, disconnected from the systems that drive decisions.
The logistics and warehousing sector have seen significant transformation in recent years, driven by technological advancements and evolving consumer expectations. As e-commerce continues to surge, businesses are under increasing pressure to optimize supply chains, reduce lead times, and provide seamless delivery experiences. This has led to a rapid shift in how warehouses and logistics networks operate.
The manufacturing industry is rapidly evolving, with the integration of Artificial Intelligence (AI) and robotics at the forefront of this transformation. As businesses look for ways to improve efficiency, reduce costs, and increase product quality, AI and robotics offer groundbreaking solutions that are revolutionizing the way products are made.
The logistics industry in the UK is undergoing a significant transformation, with sustainability becoming a central focus. One of the key trends driving this shift is the increased adoption of green logistics. As environmental concerns continue to grow, logistics companies are increasingly prioritizing eco-friendly solutions to reduce their carbon footprints and meet stricter environmental regulations.
Operations management in Manufacturing and Warehousing is at the forefront of change, utilising modern technologies as well as disciples to not only address the latest string of operational challenges, but also keep organisations running like a well-oiled machine, all the while maximising both productivity and profitability.
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