10 Challenges Manufacturers Need to Overcome When Going Online


Manish Kumawat

Last Updated on: 17 May 2024

Shifting to online platforms has become essential for business growth in every industry. When it comes to manufacturing firms that adhere to old business models and are up against severe competition from more adaptable and agile start-ups that leverage developing technology for manufacturing. A number of innovations and trends in advanced manufacturing technology are just waiting for manufacturers who want to grow digital transformation, like 3D printing, AI-powered robots, and the Internet of Things (IoT). At the same time, there are several challenges with the digitalization of manufacturing businesses. That may cause a delay in the digitalization of manufacturing enterprises.

10 Challenges Manufacturers Need to Overcome When Going Online

1. Hesitation to change

In the past, manufacturing processes functioned independently of one another, not knowing of the changes occurring at other stages. Companies face a number of issues as a result of this lack of integration, including high inventories, lost work hours, and subsequently high costs. The new technological business model allows it to quickly adjust to the latest needs. But in order for this kind of model to function, businesses must make sure of the following:

  • complete supply chain integration from beginning to end
  • agility and effectiveness at every level, including suppliers
  • Quick and transparent communication within the organization

For those, the entire assembly line process needs to change to accommodate a fresh viewpoint and style of thinking. Thus, middle management and labor both contribute to the resistance. They may wonder if the new approach will be superior to the current business plan. A software solution company like Fulminous can provide expert guidance and consultation to alleviate concerns and demonstrate the benefits of transitioning online. The consultancy team of Fulminous can ensure a smooth transition with the best strategies.

2. The initial capital for investment

It's possible that small and medium-sized businesses lack the funding necessary to both adopt and invest in new technologies. Manufacturing businesses need to have a wide perspective. Although there may be up-front investment expenditures, what is the cost of not making the technology investment to stay up with the global movement? To help manufacturers determine how much to set aside and when, what changes to make, and how to measure the results, a solid investment strategy is necessary. Including the best manufacturing website design and app development services, a software company offers cost-effective solutions and helps to solve the challenge of huge initial investment. Fulminous software has a history of helping many manufacturing businesses to step into the online realm.

3. Insufficient of knowledge and experience

A major obstacle to the digitization of production is the lack of expertise needed to safely and securely integrate modern manufacturing systems. To learn how to employ digital automation, AI and machine learning, advanced data analytics, and digital twins Manufacturing companies must work as much as possible which can increase their advanced technological capabilities. Outsourcing will be useful to lessen the burden of adoption because manufacturing companies could not have their own IT team to respond to all inquiries or offer sound operational plans. The team of experts from a top software company like Fulminous has unmatchable experience in web development, app development, blockchain, IoT, ML, and AI.

4. Security

An increasing amount of equipment is being linked via the Internet of Things (IoT) as digitalization emerges as a major global trend and growth factor. Robotics, AI, and autonomous robots are gradually replacing human labor in administrative activities; these operations are often performed unsupervised. All of this generates massive amounts of data, thus maintaining the security of all data personal and professional has become increasingly difficult and concerning over time. It is true that both management and staff are concerned about the security of personal information stored in the system. Any infraction may result in significant losses, or even worse, the failure of the entire company. Security measures in its software solutions, including encryption, authentication, and data protection protocols are implemented by our team. The focus of our team on cybersecurity make sure that manufacturers' online platforms are secure from security issues.

5. Non-flexible Infrastructure

Before manufacturers can start the process of going digital, they must overcome their current infrastructures, which are rigid and most likely incompatible with advanced technology capabilities. Begin with training is the key to digitalization. Innovative robotic activities, variable production line setups, and cloud-based resource planning are a few examples of training. A top-notch software solution-providing company can design and develop flexible and scalable digital infrastructure tailored to manufacturers' specific needs.

6. Employee Errors

One of the most frequent obstacles to manufacturing digitization is human error. The most frequent risks that businesses face, such as those related to cybersecurity, quality, and safety are to be addressed. Humans may, for instance, mishandle equipment, open unknown attachments, divulge business-sensitive information to third parties for quotation, or configure machines improperly or insecurely. Regretfully, people sometimes first find it difficult to adjust to new situations or to change. Thus, it is best not to force change if at all possible. The digital transformation’s benefits should be emphasized. A technology partner like Fulminous Software can add user-friendly interfaces and intuitive workflows into its digital solutions to minimize the risk of human errors. Well-designed training programs and ongoing support can reduce errors and enhance productivity.

7. Outdated Systems

Compared to traditional industrial equipment, which typically has an expected 10-year lifespan, technology changes far more quickly. Maintaining an antiquated infrastructure is far more difficult than maintaining a rigid one. It becomes more challenging to integrate a tending technological system with a digital industrial environment. It is common knowledge that suitable data can be exchanged between numerous systems and pieces of equipment in a contemporary digital technology environment. If corporate platforms and technology are more than five years old, it might not be feasible. Additionally, because there are many interdependencies that must be taken into account, updating technology might be difficult. A leading software solution-providing company like Fulminous Software offers modernization services to upgrade outdated systems and legacy software. Tending technologies like ML, AI, and IoT are smoothly implemented by our team to update manufacturers' digital infrastructure.

8. Privacy Issues

The major obstacle to digital transformation is privacy issues, which also include operational, personnel, and physical security since data may be exchanged readily in a completely digitalized environment. Every time data is gathered with the intention of using it to identify an individual, privacy concerns should be taken into account. This could be as simple as the contact details of staff members or clients, or it could be any type of data gathered by specific Internet of Things cameras, sensors, or biometric authentication devices. Furthermore, it's critical to understand that although information from a single device might not raise privacy concerns, information merged with information from other devices might. A top-class software company like Fulminous always prioritizes data privacy and compliance with regulatory standards in its software development process.

9. Inadequate Management of Organizational Change

The effectiveness of digital transformation might be hampered by rigid organizational structures, ineffective procedures, and inappropriate leadership philosophies. It's challenging enough to learn new technologies and procedures, but when resistance to change is added, the transformation seems unachievable. It is crucial to remember that, rather than concentrating solely on the technical aspects of digital transformation, you also need to create a thorough change management plan that takes into account the people that it directly impacts. A world-class software team like Fulminous provides comprehensive change management strategies to support manufacturers throughout the transition to online platforms.

10. Absence of a comprehensive digitization plan

Digital transformation is much more than words or conversation. However, it has been widely reported without a precise definition. This puts businesses in a position where they know they need to change, but they're not exactly sure where to begin or how. Consequently, having a plan in place is essential; otherwise, your transition could not succeed. Consider the following before putting your plan in writing: What are the priorities and goals of my company? Do they adhere to the same standards throughout the company, or are some departments in total disagreement? As a leading software solution company Fulminous Software focuses on collaborating closely with manufacturers is essential to developing comprehensive digitization plans aligned with their business goals and objectives.

Digitalization/ Software Solutions For Manufacturing Business from Fulminous Software

Software Solution Description
Website Development We design, develop, redesign, and maintain websites for manufacturing companies
Mobile App Development We develop applications for manufacturing companies to enhance customer engagement and user experience.
Machine Learning (ML) With ML, we Utilize algorithms and statistical models to analyze data, optimize processes, and make predictions for improved efficiency and decision-making.
Internet of Things (IoT) Connecting physical devices to the internet is made smooth by us to collect, analyze, and exchange data, enabling remote monitoring, control, and automation.
Artificial Intelligence (AI) (IoT) Implementing AI algorithms to automate manufacturing processes, optimize resource allocation, and improve product quality and predictive maintenance is our expertise.
Enterprise Resource Planning (ERP) Systems Integrating core business processes such as production planning, inventory management, supply chain management, and financials into a single system for real-time visibility and streamlined operations is another service of ours.
Product Lifecycle Management (PLM) Software Managing the entire lifecycle of a product from conception, design, and manufacturing to service and disposal, enabling collaboration and improving product quality and time-to-market.
Manufacturing Execution Systems (MES) Monitoring and controlling manufacturing processes on the shop floor in real-time, tracking production progress, and ensuring quality and compliance.
Computer-Aided Design (CAD) Software Allowing engineers and designers to create detailed 2D and 3D models of products and components, facilitating product design, prototyping, and simulation.
Supply Chain Management (SCM) Software Optimizing the supply chain by managing procurement, supplier relationships, inventory, and logistics to improve efficiency and reduce costs.
Quality Management Systems (QMS) Managing and controlling quality processes including inspections, audits, non-conformances, and corrective actions to ensure compliance with quality standards and regulations.
Asset Management Software Tracking and maintaining physical assets such as machinery, equipment, and facilities to optimize asset utilization, reduce downtime, and prolong asset life.
Predictive Maintenance Systems Analyzing equipment data to predict maintenance needs, preventing unplanned downtime, optimizing maintenance schedules, and reducing costs.
Manufacturing Analytics Software Analyzing data from various sources to gain insights into production performance, quality, and efficiency, identifying trends, optimizing processes, and making data-driven decisions.
Shop Floor Control Systems Managing production activities in real-time including scheduling, job tracking, and resource allocation to optimize production flow and increase productivity.

Move to Online and Grow Your Manufacturing Businesses

The information described above shows the importance of moving your manufacturing company online. Moving your manufacturing business online is not an option, but it is essential for growth in the current digital world. Collaboration with a top-notch technology partner will be a game changer and breakthrough for your manufacturing business.


Manish Kumawat

IconVerified Expert in Software & Web App Engineering

I am Manish Kumawat, co-founder of Fulminous Software, a top leading customized software design and development company with a global presence in the USA, Australia, UK, and Europe. Over the last 10+ years, I am designing and developing web applications, e-commerce online stores, and software solutions custom tailored according to business industries needs. Being an experienced entrepreneur and research professional my main vision is to enlighten business owners, and worldwide audiences to provide in-depth IT sector knowledge with latest IT trends to grow businesses online.

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