Why the gap persists
This challenge of siloed solutions is reinforced by underlying system complexity. Many organizations still rely on legacy OT systems (50%), as well as standardized control approaches or custom middleware integrations that can be costly, complex, and difficult to scale. As a result, even well-funded automation initiatives often remain isolated rather than delivering end-to-end operational impact.
As production environments become more dynamic, facilities are increasingly requiring real-time coordination across systems.
From automation to orchestration
As manufacturers connect IT and OT systems, many are discovering that integration alone does not create end-to-end autonomous operations. While automation executes individual tasks and integration enables systems to share data, it is orchestration that coordinates workflows and drives execution across those systems in real time. Orchestrated operations enable manufacturers to:
- Trigger workflows in real-time based on demand
- Coordinate activities across plant and enterprise systems
- Reduce manual intervention in execution
- Improve responsiveness to changing production conditions
Research suggests that manufacturers with connected operations can achieve up to a 20% increase in production output and productivity, while unlocking up to 15% additional capacity.
How FactoryTalk Orchestration software fills this gap
To enable this level of coordination, manufacturers need more than point-to-point integrations. They need a central orchestration layer that connects enterprise systems (such as MES, WMS, ERP) and scheduling platforms with plant-floor technologies like AMRs, fleet managers, PLCs, conveyors, robotics, and simulation tools.
FactoryTalk® Orchestration™ software was designed to fill this role. Acting as the central orchestration layer across IT and OT systems, it:
- Translates information between systems
- Coordinates workflows and execution
- Optimizes performance using real-time operational data
How FactoryTalk Orchestration software improved space utilization by 70%
At the Rockwell Automation Twinsburg facility, an initial deployment combining integration and AMRs generated approximately $162,000 in annual labor savings. With the addition of FactoryTalk Orchestration software, the facility achieved a 20% increase in operational efficiency, reduced work-in-process inventory by 50%, and improved space utilization by 70%.
OTTO® AMRs in action at the Rockwell Automation Twinsburg facility.
As manufacturers continue their digital transformation journeys, integration will remain a critical foundation. The greatest gains will come from organizations that move beyond connecting systems to orchestrating them.
Learn more about how FactoryTalk Orchestration software helped the Twinsburg facility coordinate workflows, connect IT and OT systems, and accelerate the path toward autonomous material movement in this webinar.
