The Hidden Cost of Excel in Manufacturing: 45 Hours of Debugging Every Month, Finds Copia Automation
While 92% invest in upskilling, 47% still use spreadsheets for code management; Report calls for Industrial DevOps to address skills gap and meet employee needs.
NEW YORK, Feb. 11, 2025 /PRNewswire/ -- A new report from Copia Automation, the Industrial DevOps Platform and leader in AI for Industrial Code, reveals the hidden costs of relying on outdated tools in the manufacturing and distribution sectors. The 1st Annual State of Industrial DevOps Workforce Report: People, Process, and the AI-Powered Future exposes that manufacturers lose an average of 45 hours every month to debugging tasks, largely due to reliance on outdated tools like Excel for managing critical industrial code in 47% of organizations.
Amidst a backdrop of potential shifts in trade policy and growing concerns over tariffs impacting the US, Canada, Mexico, China, and other nations, the report underscores the urgent need for manufacturing and distribution organizations to enhance efficiency and adaptability. Whether or not these tariffs proceed as planned, the likelihood of continued uncertainty in the foreseeable future is high. Organizations will need to hedge their bets to balance risk and plan for this uncertainty. With a potential resurgence in localized demand, similar to the pressures experienced during COVID, companies that invest in modernizing their operations will be best positioned to adapt and thrive.
Key survey findings reveal opportunities for improvement:
- 47% of manufacturers and distributors use Excel to manage industrial code, despite its limitations for version control and collaboration.
- Manufacturers and distributors spend an average of 45 hours per month debugging code, highlighting the significant impact of inefficient processes and tools on productivity.
- 92% of organizations invest in upskilling, yet the persistence of outdated practices like using Excel for code management undermines these efforts.
- Employees prioritize work-life balance and access to modern technology, indicating a need for manufacturers and distributors to adopt tools that streamline workflows, drive collaboration, and enhance job satisfaction.
- Only 3% of industrial coders are classified as beginners, indicating a lack of new talent entering the field and - as 10,000 workers reach retirement age each day in the U.S. - a key opportunity to close the skills gap through mentorship opportunities and knowledge exchange before it's too late.
The report's findings expose the hidden costs of relying on outdated technology and processes. While 92% of manufacturers invest in training, these investments are often rendered ineffective by the continued use of tools like Excel, which contribute to errors, hinder collaboration, and ultimately impact the bottom line, along with employee experience and recruiting efforts. The data suggests that organizations can significantly benefit from adopting modern Industrial DevOps practices.
"The manufacturing and distribution landscape is facing a period of uncertainty, with tariffs and global trade dynamics creating both challenges and opportunities," said Copia Founder and CEO Adam Gluck. "Our report's findings underscore the critical need for these organizations to prioritize efficiency and adaptability. Regardless of the specific outcome of current trade discussions, building resilience to navigate uncertainty is paramount. By embracing Industrial DevOps principles and moving away from outdated and unsustainable tools, companies can streamline operations, reduce costly downtime, and empower their workforce to meet fluctuating demands. Investing in these areas now will be crucial for maintaining competitiveness in the evolving global market."
The 1st Annual State of Industrial DevOps Workforce Report provides a roadmap for manufacturers and distributors seeking to enhance their operational resilience. By prioritizing people, process, and technology, these organizations can gain more efficiency and agility to navigate uncertainty, meet evolving customer needs, and achieve sustainable growth in the face of uncertainty and change.
About the survey
The survey contains responses from 200 executives, including C-Suite (42%), SVPs/VPs/ Heads of Department/Directors (38%), and Managers (20%). Respondents primarily came from the hi-tech, electronics, and semiconductor (21%), automotive (19%), and retail (18%) industries. Company revenues were over $15B (30%), $1B to $15B (28%), and $300M to $999M (28%).
About Copia Automation
Copia Automation delivers an Industrial DevOps Platform that empowers enterprises - large, mid-sized, and small - to effectively manage their operational technology, achieving industrial automation success. Copia's cloud-based Industrial DevOps Platform empowers companies with unparalleled visibility, governance, and control of automation code across multi-vendor devices. This provides a single source of truth, which enforces continuous quality control, increased uptime, automated backup, disaster recovery, and preemptive crisis management. With the recent addition of AI-powered features like Copia Copilot, Copia Automation continues to drive the future of industrial automation forward.
With its headquarters in New York City, Copia Automation is a member of the World Economic Forum as a Technology Pioneer in Manufacturing.
For more information, visit www.copia.io.
SOURCE Copia Automation
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