AI and Digital Tools

Where survey respondents offered general skepticism about AI, machine tool makers reveal a wider spectrum. Klingelnberg represents the advanced end, with Daniel Meuris, head of digitalization and virtualization, describing deployment of “big data analytics extending to machine learning technologies and LLM agents,” integrated into both internal processes and customer-facing products.

Most companies occupy more modest territory. Helios uses AI for communications support. Machine Tool Builders employs it for contracts, text editing, and reducing reporting burdens. Wegryn-Jones offers a characteristically grounded assessment: “All that AI is actually doing is duplicating what a stenographer would have done in 1960 or a copy editor in 1970 or perhaps an intern in 1980.” That said, he acknowledges its spreadsheet capabilities are “remarkable, useful, and do save some significant amounts of time.”

Which digital initiatives have delivered real returns? Gleason reports that closed-loop corrections and optimizations are “proven value adders,” and its Fingerprint status monitoring solutions provide genuine value for predictive maintenance. Klingelnberg’s Meuris observes an inverse relationship between complexity and clear ROI: simple connectivity technologies like MQTT or OPC UA deliver immediate value, while larger initiatives require longer horizons.

Hollingsworth sees condition monitoring as the clearest opportunity: “If you can plan your downtime, you reduce your downtime.” The value proposition is straightforward—a moderate investment upfront against reduced unplanned stoppages.

Beyond analytics, Hollingsworth points to a quieter revolution: software has become “an equivalent IP aspect to machines as compared to the inherent mechanical design.” The capabilities unlocked through software development, often on essentially unchanged hardware, now matter as much as the iron itself.

Helios offers a contrarian view on IIoT: it “had its moment,” but tariff disruptions and industry uncertainty pushed those projects aside. AI has taken center stage because it delivers immediate, visible value. IIoT will return, but for now it’s waiting in the wings.

The Workforce Puzzle
Companies are responding to the experience gap on multiple fronts. Klingelnberg has implemented dynamic digital manuals for manufacturing and assembly that incorporate operator feedback, preserving process knowledge in accessible form. The company’s grinding assistant software embeds expert knowledge directly into the operator interface, supporting less experienced workers in setting up effective processes.

Liebherr has expanded remote support capabilities and developed modern training simulators. Helios maintains a pipeline through partnerships with local universities and technical schools, offering internships and part-time positions while documenting processes in digital formats that accelerate onboarding.

Nidec takes a different approach: making machines themselves more intuitive. “If we can bake the expertise of a 30-year veteran directly into the software and the user interface,” the company explains, “it makes the learning curve much more manageable for the next generation entering the trade.”

GMTA’s Hambleton sees reasons for optimism: “It is exciting to see more companies take the initiative and offer training, apprenticeship, and mentorship programs. Young people need other options to a four-year university degree.”

Hollingsworth frames the challenge more bluntly. Germany’s apprenticeship programs start young adults early in machine tool careers, but the deeper problem is cultural: “For many years manufacturing was given a negative connotation and tech was the ‘pushed’ career path in schools. We need to change the culture and perception in North America that manufacturing offers rewarding and successful career options.” Training systems exist; the pipeline of people entering them does not.

Gleason’s Perrotti connects workforce to strategy. When asked about reshoring, he redirects to what he sees as the prerequisite: “First you need a large enough, trained workforce. This needs to be the top priority to expand the industrial base.”