Imagine running industrial systems that can evolve in real time, rapidly respond to shifting demands and autonomously optimize operations. That’s the promise of adaptive production, a transformative force that can give you an edge in the face of constant change.
Adaptive production is a smart manufacturing approach that uses real-time data, AI and automation to continuously adjust processes. It enables fast responses to changes in demand, supply or operations – improving efficiency, agility and flexibility without needing to overhaul existing automation systems.
Merging IT and OT allows for:
Combining the real and the digital worlds enables data-based concepts and AI copilots that allow you to optimize and adapt production for new products.
An adaptive business empowers its teams with real-time responsive systems. They can adapt to change with confidence, backed by trustworthy data.
Adaptive production allows manufacturers to stay flexible and competitive by applying IT and software development methods to automation.
Discover what the future of automation looks like and how to achieve it.
An adaptive business empowers its teams with real-time responsive systems. They can adapt to change with confidence, backed by trustworthy data.
Adaptive production allows manufacturers to stay flexible and competitive by applying IT and software development methods to automation.
Is adaptive production right for you? Can you build on your current automation setup? Annemarie Breu, our expert, answers the most common questions.
Adaptive production shifts manufacturing from static efficiency to dynamic resilience. Using AI, software-defined automation and IT-like engineering, it enables real-time responses to disruptions while supporting –not replacing – workers. Scalable for all business sizes, it relies on plug-and-play tech to optimize production without requiring deep technical expertise.
While flexible manufacturing handles product changes, adaptive production responds to all process conditions – like equipment behavior and supply shifts. It monitors performance, detects quality issues and adjusts in real time, improving yield, quality and throughput across any production mix or volume.
Adaptive production uses a layered tech stack built on existing systems, ideal for brownfield sites. Edge computing enables real-time functions like inspection and predictive maintenance. By integrating data from machines, software and schedules using graph databases, it creates a unified production model. Generative AI and large language models then make insights accessible through plain-language queries.
Adaptive production creates a closed feedback loop – from sensing to action. Edge devices detect issues in real time, while graph-based models enable root cause analysis. Generative AI translates data into intuitive answers, and corrective actions can be automated. This continuous loop drives smarter, more efficient and flexible operations.
In these so-called brownfield settings, adaptive production augments rather than replaces existing systems. Edge computing and intelligent sensors layer onto legacy equipment, capturing diverse data. Through semantic modeling, this data is unified to enable AI-driven monitoring, root cause analysis and self-optimization – scalable without major infrastructure changes or disruption.
Tyson Foods, a U.S. food company, showcases adaptive production in action, using AI copilots to support shift planning with historical data. High adoption came from seamless workflow integration and minimal change management. Success depends on strong data foundations and user-centered design – engaging frontline workers early. The result: better performance, faster problem-solving and more attractive, tech-enabled workplaces.
Learn how customers leverage our technologies to harness Industrial AI for data analysis and optimized decision-making, maximize IT/OT convergence, and accelerate digital and sustainability transformations at scale.
Totally Integrated Automation (TIA) and Industrial Operations X make your production highly automated and adaptive. Combine IT with OT expertise to experience automation at the speed of software development.
Our approach to adaptive production builds on existing automation systems by integrating IT capabilities and maintaining a human-centered focus.
