Modicon IIoT-native PLCs manage complex interfaces, with embedded functional safety and cybersecurity.
Schneider Electric
Manufacturing is evolving fast. As with any change, it’s creating both opportunities and challenges in its wake. We’re seeing more plants adopt digital tools to improve efficiency, reduce downtime, and make better decisions in real time. As automation scales, so does complexity and the need for strategic investment.
But getting your business to the next level isn’t just about buying new tech; it’s about knowing how to integrate it into your operations in a way that makes sense for your business.
At Schneider Electric, we understand every stage of this journey and help original equipment manufacturers (OEMs)make the transition in a way that’s practical, scalable, and smooth. That’s why we’re focused on innovation, strong partnerships, and investment aimed at building a more resilient future for U.S. manufacturing.
Digital-first, future-ready
As industries respond to the need for greater productivity, quality, and customization, the demand for smart machines, including industrial robotics, is growing fast. Automation and advanced digitalization are enabling machine builders to design systems that are more connected, data-driven, and adaptable.
A food manufacturer recently faced challenges with unreliable controls on their cookie dough processing machines—equipment that plays a key role in shaping cookies before they’re baked. These machines were originally using control systems from another supplier, which weren’t meeting the manufacturer’s reliability or performance needs. To solve this, Schneider Electric partnered with DSI Innovations, a trusted system integrator, to deliver a more dependable and efficient automation solution. This collaboration brought together Schneider Electric’s advanced automation technology and DSI’s integration expertise to transform the manufacturer’s operations.
Together, we upgraded the system using Schneider Electric’s Modicon PLCs, variable speed drives, and user-friendly operator interfaces. One of the key benefits of this solution was how easy it was for DSI to create a functional template across 16 drives connected over ethernet to monitor the status of the process. Schneider Electric worked alongside with DSI to better leverage IO scanning with implicit Ethernet/IP communications to the Variable Frequency Drive (VFD) —simplifying programming and reducing engineering time and reducing the chance of errors.
Using Schneider’s EcoStruxure Control Expert software, DSI created a reusable programming template for the drives. This meant they could set up one drive and then quickly apply the same setup to the others, which streamlined the entire process. The result was a cleaner, more organized control system that’s easier to maintain and scale.
Schneider Electric engineers also supported DSI in building the operator interface using EcoStruxure Operator Terminal Expert. They helped with everything from designing intuitive graphics to setting up alarms, trends, and recipe management—making it easier for operators to monitor and control the machines.
This collaboration between the food manufacturer, DSI Innovations, and Schneider Electric not only improved machine reliability but also sped up deployment and simplified future maintenance. It’s a great example of how working together can deliver smarter, more efficient solutions for OEMs and end users alike.
Achieving resilient manufacturing requires a strategic, integrated approach, cross-functional collaboration, and a specialized partner ecosystem that brings deep domain expertise, high performance, and scalable industrial solutions.
Closing the skills gap through collaboration
The biggest barrier to integrating and maintaining advanced automation solutions isn’t hardware — it’s talent.
As experienced automation professionals retire and a new generation enters the workforce with less hands-on experience, the industry faces a critical shortage of skilled integrators, programmers, and technicians. At the current pace, nearly 4 million manufacturing jobs will be unfilled in the next decade.
No single company can solve the talent crisis alone. That’s why Schneider Electric is investing in collaborative ecosystems that bring together OEMs, system integrators, educators, and technology partners to facilitate knowledge transfer and workforce development programs.
One way Schneider Electric is putting this approach into practice is through its new Robotics & Motion Center of Excellence in Raleigh, NC. Here, community members, including students, manufacturers, integrators, distributors, and more, can co-develop and test robotic applications with experts, access hands-on training in motion control, AI, and digital twin technologies, and explore real-world use cases across industries. By making advanced robotics more accessible, Schneider Electric is helping manufacturers bridge the gap between ambition and implementation.
This center is part of a broader commitment to an investment in U.S. industry. Schneider Electric has recently committed to a $700 million investment in U.S. operations through 2027. The goal of this investment is to expand domestic manufacturing capacity, develop AI-ready automation infrastructure, and support over 1,000 new jobs in engineering, manufacturing, and technical services.
PMMIThis commitment is also reflected in Schneider Electric’s partnership with The PMMI Foundation as its newest Visionary Benefactor. In this role, Schneider Electric is supporting scholarships, educational programs, and workforce development initiatives that prepare the next generation for careers in the packaging and processing industry.
The road ahead
The future of manufacturing is smarter, faster, and more connected than ever. Schneider Electric is not just keeping pace with change but driving it. With the right technology, the right partners, and a shared commitment to innovation and workforce development, we’re helping manufacturers turn complexity into competitive advantage.
Hiring remains a major challenge in packaging, with 78% struggling to fill unskilled roles and 84% lacking experienced workers. As automation grows, companies must rethink hiring and training. Download the full report for key insights.
