There is an interesting national debate about what manufacturing should look like in the future, and it certainly includes the plastics processing industry.
It is easy to think nostalgically about lunchpail-toting workers streaming out of the factory gate at the end of their shift. Lots of Americans were employed, wages generally supported a middle-class lifestyle, and there was a clear career path for those who did not necessarily want to go to college.
Training? Just show up every day and you would be shown what to do. Do it well and move up the ladder to a slightly better job in the factory.
The good old days!
Now we are in an era of transition from mass production to lean manufacturing and automation.
A recent article in the New York Times asked if America has what it takes to make things again. Can President Trump’s tax on goods imported from other countries bring jobs and factories back to the United States?
There are significant problems with reviving manufacturing here. First, there is a people problem. There are currently about 622,000 unfilled manufacturing jobs, according to John Dorer, an expert on workforce development and labor shortages. The broader U.S. labor force has about 1.7 million vacant positions.
Wells Fargo economists have calculated that to get manufacturing back to its 1970s peak, 22 million workers would need to be hired.
There are also big problems with training, technology and government support for manufacturing, according to the Times.
The Information Technology & Innovation Foundation reported in late 2024 that Census Bureau data shows a steady decline in U.S. manufacturing even while the overall economy has grown. China surpassed the U.S. as the world manufacturing leader in 2010 and now produces $2.4 trillion more manufactured goods.
Dimitar Dimitrov, managing partner at custom software developer Accedia, wrote in Forbes, “The future of manufacturing lies in embracing innovation and adaptability. As the industry evolves, companies that invest in forward-thinking technologies and sustainable practices will be better equipped to capitalize on emerging technologies.”
That does not sound like a description of the typical factory of the 1970s.
It was in the late 1970s that I visited a U.S. auto assembly plant for the first time. I was appalled at the inefficiencies I saw. There is no wonder that auto assembly has suffered such huge job losses.
We need to get over our notions of past manufacturing glory and embrace the future, which will include far fewer people producing far more products.
The U.S. plastics processing companies that are thriving are the ones embracing technology. That is especially true in mold making, which is evident in three stories by Senior Staff Reporter Karen Hanna in our July issue.
Here are what experts say are the keys to our manufacturing future:
Industry 4.0 and smart manufacturing: Industry 4.0 describes the integration of artificial intelligence (AI), Internet of Things (IoT) and automation to create smart factories. Smart manufacturing enables real-time monitoring of production, predictive maintenance and optimization of manufacturing operations, according to training firm SolidProfessor.
Sustainable practices: Reducing waste, conserving resources and minimizing the environmental impact of production processes. Sustainable manufacturing can also lead to cost savings by reducing energy consumption and material waste.
Additive manufacturing: This technology enables rapid prototyping; customization; and on-demand production to reduce the time and cost of product development, enable mass customization, and create new revenue streams through the production of spare parts and replacement components.
Human-machine collaboration: As automation and AI become more prevalent, there is a growing need for human-machine collaboration. This involves combining the strengths of humans and machines to create a more efficient and productive manufacturing process.
Management consulting firm Kearney hosted a conference on the future of manufacturing, and this is one of the ideas that came out: “Incredible technologies are emerging faster than most people can understand them. But while exciting advancements such as generative AI are powerful enablers, they are never going to be a magic bullet for solving operations challenges. Technology can help improve productivity and bolster the power of your human workforce, but especially in today’s tight labor market, manufacturers must invest in their people to use the tools at hand efficiently and responsibly.”
It is not correct to think that our manufacturing system has failed, but you can make an argument that we sat on our haunches while others sprinted ahead.
Your plant can be part of the renaissance in manufacturing. Embrace lean, invest wisely in smart technologies and hire people for tomorrow’s jobs.
Ron Shinn | Editor
Editor Ron Shinn is a co-founder of Plastics Machinery & Manufacturing and has been covering the plastics industry for more than 35 years. He leads the editorial team, directs coverage and sets the editorial calendar. He also writes features, including the Talking Points column and On the Factory Floor, and covers recycling and sustainability for PMM and Plastics Recycling.
