Manufacturers enter a critical phase of AI adoption as focus shifts from pilots to enterprise transformation
Chicago, July 9, 2026
CHICAGO, JULY 2026 – Manufacturers are accelerating their adoption of artificial intelligence, moving beyond isolated pilot programs toward enterprise-wide transformation, according to new research conducted by Manufacturers Alliance Foundation with support from Roland Berger. Based on a survey of more than 100 manufacturing leaders and nearly 40 executive interviews, The Great Acceleration: Scaling AI from Tactical Pilots to Strategic Transformation finds that leading manufacturers are increasingly treating AI as a strategic business capability rather than a standalone technology initiative.
While many organizations remain in the early stages of their AI journey, the research shows that a growing number have successfully scaled pilots and are integrating AI across functions and business units. At the same time, manufacturers report that preparing data for AI and building workforce capability have become more significant challenges than initially expected.
“Manufacturing is entering a new stage of AI maturity,” said Gareth Hayes , Senior Partner at Roland Berger. “The leaders are no longer asking whether AI can create value. They are asking how quickly they can scale it across the enterprise. What distinguishes the frontrunners is their ability to combine a strong data foundation, a clear transformation strategy and workforce engagement around a common vision.”
The report identifies three distinct groups emerging across the manufacturing landscape: organizations taking a wait-and-see approach, manufacturers pursuing a portfolio of test-and-learn initiatives, and a small but growing AI vanguard that is actively redesigning operating models around AI capabilities.
Data quality remains the most frequently cited barrier to AI deployment. Nearly two-thirds of surveyed manufacturers reported that significant data clean-up and preparation was required before launching AI initiatives, while only a small minority indicated their data was immediately AI-ready. [
“Many organizations underestimate the importance of data readiness,” said Philipp Leutiger , Senior Partner at Roland Berger. “However, perfection should not be the goal. Companies that generate the most impact focus on solving business problems with the data available today while continuing to strengthen their broader data foundation over time.”
The research also suggests that concerns about workforce resistance to AI have declined significantly over the past two years. Instead, manufacturers increasingly view AI as a tool to augment employees and improve decision-making, creating demand for new approaches to training and skills development.
“When you look at successful AI transformations, technology is only part of the equation,” Leutiger added. “The larger challenge is helping people understand, trust, and adopt new ways of working. In many cases, AI success is driven more by organizational readiness than by technological capability.”
Looking ahead, manufacturing executives expect AI to play a central role in improving productivity, strengthening supply chains, accelerating innovation, and enabling more customer-centric operations. The report concludes that the pace of AI integration will be determined less by technological limitations and more by an organization's ability to align leadership, workforce capabilities, and enterprise data strategies.
About the research
The Great Acceleration: Scaling AI from Tactical Pilots to Strategic Transformation is based on a survey of more than 100 mid- to large-cap manufacturing companies and interviews with nearly 40 manufacturing executives, technology leaders and industry experts. The research was conducted by the Manufacturers Alliance Foundation with support from Roland Berger.
Further information
Read the full report:
The Great Acceleration – Manufacturers Alliance
Related Roland Berger insights:
Profitless Prosperity in AI
