The manufacturing industry is approaching a critical juncture, with research revealing that 83 per cent of manufacturers report difficulties recruiting skilled workers. This is the result of an ageing workforce coupled with changing job requirements, and a lack of awareness about career opportunities in the sector.
The current generational divide is leading to a lack of cohesion between members of the workforce, with 41 per cent of manufacturing workers aged 60 - 66 say their skills are going unused. However, most young workers are more than willing to learn from their older colleagues.
Clearly, there is a huge potential for the sector to take advantage of the experience of many of its workforce before they retire, and their vital skills are lost. We have spoken to a number of experts across the sector on how businesses can address this issue, and how the latest technology could help bridge the skills gap by supporting the next generation of workers.
The widening skills gap
There can be no doubt that the manufacturing industry is facing an ever-expanding skills gap, which is why Claire Hu Weber, Vice President of International Markets at Fluke Corporation, urges “it’s no longer just ‘important’ to bring young people into manufacturing, it’s mission critical. The skills gap is widening year after year, and the numbers don’t lie.
“Add to that the fact that women make up barely a quarter of the UK manufacturing workforce, we don’t only have a lacking workforce pipeline but a lack of diversity too. Unless we move fast to attract new talent and break down the barriers that keep women from entering and staying in the industry, we’ll lose not just capability, but the diversity of thinking that fuels real innovation and growth.”
For Hu Weber, “this sector doesn’t need polite conversation, it needs urgent action. Every leader has a responsibility to step up, make inclusivity and growth pathways non-negotiable, and to do it now - before the gap becomes impossible to close.”
Michael DeMaria, Director of Product Management at Fluke Reliability, expands on this point further, emphasising that “we don’t just have a skills gap; we have a capability gap.
“As experienced workers retire, industries risk losing the situational knowledge built through decades of trial, error, and high-stakes decision-making. At the same time, the next generation brings a new mindset – they expect smarter ways of working, tools that prevent unnecessary mistakes, and careers that are sustainable: mentally, physically, and professionally.
“The strategic path forward is to capture that lived experience and translate it into scalable systems. AI can help make this possible by embedding veteran expertise into guidance that helps new employees adapt quickly, avoid preventable failures, and focus on continuous improvement.”
Harnessing key knowledge
According to Mark Williams, Managing Director EMEA at WorkJam: “The frontline workforce is often seen as the backbone of the manufacturing industry. They are the ones who produce, move, and maintain products to ultimately get the job done. Yet, workforce challenges continue to plague the sector, with 75% of manufacturers identifying skills shortages as their biggest barrier to growth. It is vital for companies to focus on investing in the frontline in order to mitigate these skills gaps, boost operational productivity and achieve success for the future.”
For Jesus Hernandez, Senior Vice President, EMEA at AVEVA: “With many experienced people retiring over the next few years, the industry needs to consider other means of upskilling.
"It is important to look at how skills and experience can be transferred from seasoned professionals to younger members of an organisation. True expertise in manufacturing does not come from simply following instructions; it comes from understanding the ‘why’ behind every decision, whether that relates to safety, regulations, or technical processes.”
WorkJam’s Williams reminds us that “a motivated, strong and capable manufacturing workforce boosts productivity and operational performance. Prioritising the retention and engagement of the frontline is key to upholding the industry and allowing it to remain as a key player in the UK economy.”
Support from robotics and AI
It is clear that as the workforce develops, upgraded technology will play a key supporting role. As Volker Spanier, Head of Manufacturing Solutions at Epson EMEA, explains: “With robotics advancing rapidly, we are entering a new era in which machines are no longer rigid, single-task tools. Instead, they are flexible, reprogrammable partners – cobots designed to collaborate with people across a wide range of roles. Far from replacing workers, these intelligent systems take on repetitive or hazardous tasks, freeing people to focus on creative, strategic, and value-adding work. This evolution not only enhances productivity but also helps create safer, more inclusive workplaces that attract a wider talent pool into the sector.
“The increasing accessibility of smart robotics, with simpler software, increased affordability, and designed to be more reusable, means UK manufacturers of all sizes can embrace automation. This democratisation of advanced technology represents a turning point: one where robotics strengthens the UK’s manufacturing excellence and global competitiveness.”
The manufacturing industry is constantly evolving, and in addition to advancements in robotics, Simon Bowes, CVP Manufacturing Industry Strategy EMEA at Blue Yonder, emphasises that “Artificial Intelligence is a critical enabler. Predictive demand planning powered by AI helps manufacturers anticipate fluctuations, reduce overproduction, and align supply with real needs.
“But technology alone is not enough. Adoption requires people. This makes investment in skills and career development just as vital as investment in technology. Hand in hand it will empower today’s workforce to take on higher-value roles and inspiring new generations to view manufacturing as a dynamic, purpose-driven career.”
AVEVA’s Hernandez echoes this sentiment, highlighting how “forward thinking manufacturers are now also making the most of integrated AI-assistants. These provide guidance and assistance 24/7 to junior team members, imitating the expertise of senior employees with decades of practical know-how. By providing AI guides to turn to, businesses can offset the dilemma so many are facing: an aging workforce that is retiring and taking its hard-earned knowledge with them.”
Bowes concludes: “Manufacturing Day is therefore a call to action: accelerate innovation, equip people with the tools and skills they need, and build ecosystems where sustainability, resilience, and talent converge.
“The future is already here, and it will be shaped by those bold enough to embrace it.”
