In today’s rapidly evolving industrial landscape, staying ahead requires companies to become more nimble, proactive and aligned in how they innovate, make, and sell products. Forward-thinking manufacturers are embracing digital thread solutions to transform operations by seamlessly connecting IT and OT across the enterprise. This integration enables a continuous flow of data across the manufacturing value chain, breaking down silos between design, manufacturing, and maintenance to drive innovation, efficiency, and resilience. By uniting people, processes, and technology, organizations can accelerate transformation, maximize workforce productivity, and optimize operations - positioning themselves to thrive amidst constant change.
Accelerate Digital Transformation with the Digital Thread
The potential of Digital Transformation is clear
50%
Reduction in unplanned downtime
97%
Lower ramp-up defects
40%
Reduction in maintenance cost
90%
Improvement in right-first time quality
Achieving these outcomes is possible through the implementation of a robust digital thread strategy
Achieve your potential with Digital Thread Solutions
Accelerate innovation
Success in manufacturing hinges on the ability to innovate swiftly. By leveraging the digital thread, companies can connect stakeholders and data globally in the cloud, facilitating early and frequent collaboration during the design process and seamless transfer to manufacturing.
Reduce time-to-quality
Optimize manufacturing processes in a virtual environment prior to investing in the physical world. Empower engineers to simulate every aspect of production and virtually commission machines without needing access to a single piece of equipment.
Accelerate time-to-market
Remove dependencies by bringing every stakeholder together in real time from the start. Kick off product design, machine design, and production engineering simultaneously to reduce timelines and evaluate design manufacturability.
Maximize workforce productivity
With 58% of the workforce approaching retirement and processes that are becoming increasingly complex, it is time to empower your rapidly changing workforce.
Capture expertise from top operators
Scale manufacturing expertise across the workforce with Augmented Reality. Expert operators can improve standard operating procedures by quickly documenting and sharing their standards of excellence with the enterprise.
Accelerate employee ramp time
Empower your workforce to reach their potential with high-fidelity training and on-the-job instruction. With access to hands-free, step-by-step directions, new personnel are equipped to deliver a first-time fix their first day on the production floor.
Optimize operations
The key to optimizing operations is connecting the plant to the digital content created by other business functions. You can reduce 70% effort from data science projects by automating OT/IT convergence.
Automate IT/OT convergence
Harvest scalable insights with an information model optimized for Digital Thread. Our Common Information Model drastically reduces the effort required for industrial analytics by building OT data context at the source.
Enable lights-out manufacturing
Increase manufacturing flexibility and agility by removing friction between enterprise systems. Download and execute orders, at any plant and line around the world, without human intervention.
Automate workflows
Keeping up with demand typically requires coordination across many systems. Automate those workflows to orchestrate production and then allocate resources across your operations and the supply chain.
Why partner with Rockwell Automation?
Rockwell Automation delivers digital transformation and the digital thread that brings the connected enterprise to life and transforms product innovation
What is a Digital Thread in Manufacturing?
The digital thread is a seamless flow of data that connects business processes, systems, products, and equipment across the value chain to deliver business growth, operating efficiency, cost reduction, resiliency and risk mitigation. In manufacturing, a digital thread links traditionally siloed systems like computer-aided design (CAD), product lifecycle management (PLM), manufacturing execution systems (MES), and enterprise resource planning (ERP) with smart devices and internet of things (IoT) platforms. This integration enables real-time data exchange and traceability between different stages, from design to manufacturing and maintenance. For example, if a product is designed using CAD software, that same data can be shared with manufacturing machines to automate production, while quality control systems can monitor and adjust processes based on real-time feedback.
A digital thread enables manufacturers to track a product’s progress at each step. This ensures that changes made in design or production are instantly reflected throughout the system. This results in more efficient production, reduced errors, improved quality, and the ability to customize products on-demand while maintaining a traceable record of all involved components and processes.
Digital Thread vs. Digital Twin: What’s the Difference?
A digital thread is a communication framework that connects data across a product’s lifecycle, ensuring seamless data flow from design to production and beyond. A digital twin is a virtual representation of a physical product, system, or process that mirrors real-time performance and conditions.
While a digital thread connects and contextualizes data throughout the manufacturing lifecycle, a digital twin uses that data to simulate, analyze, and predict performance.
Digital twins rely on digital thread solutions to enhance accuracy and provide deeper operational insights. Ultimately, the digital thread ensures data continuity, while a digital twin harnesses that data to create actionable insights.
Benefits of a Digital Thread
Digital thread solutions offer manufacturers with a wide range of benefits, including:
- Enhanced Traceability – Provides real-time tracking data throughout a product’s lifecycle, enhancing visibility and accountability.
- Improved Efficiency – Streamlines processes by connecting design, production, and maintenance systems, helping to reduce errors and delays.
- Better Decision-making – Provides comprehensive data for informed decisions, enabling quicker responses to issues or changes.
- Increased Collaboration – Enables improved communication across departments and teams, enhancing coordination and innovation.
- Cost Reduction – Minimizes waste and rework by identifying issues early, optimizing production, and improving overall quality.
Challenges of a Digital Thread
Despite its benefits, adopting a digital thread comes with challenges, including:
- Strategic alignment and execution: Defining a strategy, securing executive buy-in, and executing the plan effectively.
- Data Integration Complexity: Harmonizing data across different systems with varying formats and technologies.
- Data Governance: Managing, standardizing, and ensuring the accuracy of large amounts of data across a product’s lifecycle.
- Cultural Resistance: Overcoming adoption of new ways of working from teams accustomed to traditional workflows.
Digital Thread Examples
Digital threads are transforming industries by enabling end-to-end connectivity across the enterprise. Examples include:
Aerospace: Digital threads are used to track the lifecycle of aircraft components. For examples, digital threads can link design models, production data, and maintenance records to ensure seamless operations and improve predictive maintenance.
Automotive: Digital thread solutions are helping car manufacturers seamlessly integrate design data, production processes, and customer feedback. This continuous loop of data ensures that they optimize vehicle design and manufacturing, while also tracking product performance post-sale. By adopting digital thread strategies, automotive companies can improve operational efficiency, reduce time-to-market, and better respond to customer needs.
Food & Beverage: In the food and beverage industry, digital thread solutions connect data from product formulation and ingredient sourcing through production, packaging, and distribution. This end-to-end connectivity enhances traceability, supports quality and safety compliance, and enables faster response to recalls or supply chain disruptions. By linking systems and data across the lifecycle, food and beverage manufacturers can optimize production, reduce waste, and adapt more quickly to changing consumer demands and regulatory requirements.
Medical Device: The industry is increasingly adopting digital thread strategies to address evolving trends and regulatory demands. By connecting data across the product lifecycle, manufacturers streamline processes, ensure traceability, and accelerate innovation—all while improving patient outcomes.
Pharmaceuticals: In the pharma and biotech industry, digital threads are enabling end-to-end visibility and traceability across complex, global supply chains. By connecting data throughout the product lifecycle, companies can accelerate drug development, improve quality assurance, and respond more effectively to regulatory requirements. Digital threads also support continuous process verification and real-time monitoring, helping pharma organizations reduce risk, enhance compliance, and bring therapies to market faster.
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