In early 2024, ETQ surveyed 175 enterprise manufacturing firms in the UK to gather information about the state of quality management across various manufacturing sectors. Responses revealed valuable insights about quality-related trends and challenges facing UK manufacturing organizations, including predictions of quality management.

One insight stood out above the rest: In 2024, quality management in UK manufacturing is undergoing a significant shift driven by automation and AI. Let’s take a closer look at this and other UK quality management trends.

Adoption of Automated Quality Management Systems in the UK

According to our survey, 89% of manufacturers in the UK have adopted automated quality management systems. This widespread adoption is transforming the way UK manufacturers manage quality processes.

Why Automation is Essential for Quality Management

Manufacturers in the UK are increasingly recognizing the power of automation to enhance quality management. Automated systems support quality-related tasks and offer capabilities such as:

• Streamlining processes and repetitive tasks
• Reducing human error
• Enabling real-time responses to quality issues, improving efficiency
• Ensuring regulatory compliance
• Reducing downtime
• Supporting proactive adjustments, leading to better product quality and lower costs
• Facilitating continuous improvement with actionable insights

In short, automation empowers manufacturers to stay competitive by driving efficiency, ensuring consistent quality and minimizing costly disruptions. And based on the high adoption rate, it’s clear most UK manufacturers understand how beneficial automation is.

The Evolving Role of AI in Quality Management

AI adoption is on the rise, taking automation to the next level. With the power of AI, manufacturers can implement tools that lead to smarter, more efficient manufacturing operations. For example:

• Predictive analytics: AI models can identify potential issues before they occur, reducing downtime and maintenance costs.
• Real-time monitoring: By continuously tracking various environmental and equipment performance metrics, AI-driven monitoring systems enable immediate responses to quality and performance issues.
• Process optimization: With AI, manufacturers can analyze vast amounts of data to find and fix workflow inefficiencies, increasing efficiency and reducing waste.

Leveraging AI for Predictive Analytics

The ability to use AI to predict and prevent quality issues is revolutionizing the manufacturing sector. In addition to being incredibly costly, recalls are on the rise. However, when manufacturers use predictive analytics to anticipate problems before they escalate, they have a significant opportunity to save money, protect brand reputation, and maintain customer trust.

Predicting Quality Issues Before They Happen

AI-powered predictive analytics solutions use historical data to forecast future outcomes based on past patterns and trends. These insights allow manufacturers to understand the various environmental and performance factors that lead to quality issues and empower them to intervene before the issues actually occur.

By anticipating and preventing problems, manufacturers can maintain high production standards, minimize downtime and keep operations running smoothly.

Impact on Operational Efficiency and Cost Reduction

In our survey of UK manufacturing firms, 50% of respondents said rectifying their most recent product recall costs between 8 million and 39.9 million pounds (GBP). If AI-driven insights could prevent the issue(s) that might lead to the next recall, that could mean saving millions of pounds — plus the incalculable costs incurred by reputational damage.

Beyond the looming shadow of potentially costly recalls, predictive analytics also drives day-to-day operational efficiency and cost reduction for UK manufacturers. By identifying potential defects or performance problems before they occur, predictive analytics keeps daily production running smoothly — and within budget.

Empowering Frontline Workers with Data

Advancements in AI and predictive analytics are also empowering frontline workers in UK manufacturing, helping them play a more active role in quality management.

Real-Time Access to Data for Decision-Making

Providing workers with real-time data through connected devices empowers them to address quality issues immediately and make more informed quality decisions. With instant access to key metrics and customized alerts, frontline workers can:

• Detect and fix potential defects before they become larger problems.
• Optimize production workflows in real time.
• Reduce downtime and increase overall efficiency.

Increasing visibility in quality management enables a proactive approach where workers can respond to issues in real time. These real-time reactions prevent quality issues from escalating and lead to improved product quality and operational performance.

Training and Upskilling for Enhanced Quality Management

When workers have the skills and knowledge to leverage advanced tools like connected devices, wearables, predictive analytics and real-time monitoring systems, they can quickly identify and address quality issues before they impact production. Connected worker solutions also enable data-driven decision-making based on historical and real-time insights, not guesswork.

Well-trained, empowered workers are more likely to take ownership of quality control processes, ensuring smooth operations and better product consistency. Investing in training boosts productivity, employee morale and buy-in.

Overcoming Obstacles to Quality Improvement

Despite the significant benefits of AI and automation, UK manufacturers still face challenges when implementing and using these technologies for quality management.

Resistance to Change and Technology Adoption

Adopting new technologies in manufacturing often comes with challenges, including workers’ skepticism and resistance to change. AI and automation technology can create a layer of resistance, as some workers fear job displacement due to AI.

Lack of skilled personnel is another challenge manufacturers must overcome when introducing advanced technologies. Some companies struggle to find employees with the necessary skills to operate and maintain advanced AI-driven analytics platforms or connected devices. This skills gap can hinder the effective implementation of new systems, but manufacturers can overcome it by investing in robust training programs to upskill current workers.

Continuous Improvement Through Data-Driven Insights

One of the biggest takeaways from our 2024 Manufacturing Survey was that artificial intelligence in manufacturing is inevitable. To remain competitive in the coming years, manufacturers will need to figure out how to use AI strategically in their quality management efforts.

The Role of Quality Data in Continuous Improvement

Real-time monitoring provides instant feedback on production conditions, enabling workers to make adjustments before problems escalate. This proactive approach reduces downtime and minimizes defects, which leads to enhanced productivity and improved product quality.

Real-time data and predictive analytics create a feedback loop in which predictive models constantly refine their insights based on production outcomes, and production outcomes constantly improve due to the increased accuracy of predictive models.

Future Trends in UK Quality Management

As AI and machine learning technologies continue to evolve, UK manufacturers will benefit from increasingly accurate predictive models, which will enable faster detection of potential quality issues and equipment failures. As manufacturers grow more productive and efficient, they will be better positioned to reduce costs and enhance product quality.

While these advancements will help many UK manufacturers gain and maintain a competitive edge, others may struggle to keep up with advancing technology and growing market demands.

Staying Competitive in the AI-Driven Future

Surveying UK manufacturers revealed valuable insights about the current state of manufacturing and emerging trends for the future. One thing is certain — UK manufacturers must embrace AI, automation and data-driven strategies to stay competitive. For more survey insights, download the full report.