According to the overall barometer value of the MHP Industry 4.0 Barometer, the degree of digitization in industry is increasing worldwide, although no longer as rapidly as in the past. China and the USA are further extending their lead over the DACH region. And especially in the German-speaking countries, the lack of specialists and old systems are hindering the expansion of data-driven production.

Distribution and degree of maturity of Industry 4.0 technologies

These are the key findings of the Industry 4.0 Barometer, which was compiled by the management and IT consultancy MHP together with the Ludwig Maximilian University of Munich (LMU). A total of 823 individuals from industrial companies in China, the United States, Germany, Austria, Switzerland and the United Kingdom were surveyed. The study covers the prevalence and maturity of Industry 4.0 technologies, provides a comparison of the status quo between countries and highlights development trends since 2018. The study for decision-makers also includes specific recommendations for action and success stories from user companies, as well as interviews.

Staying connected in international competition

Markus Wambach, Group COO at MHP: “For seven years now, we have been publishing the barometer together with the LMU Munich, which initially reflected the Germany-wide Industry 4.0 benchmark and has been measuring and comparing the degree of maturity internationally since 2021. On the one hand, the barometer is a mirror for companies that shows current developments and challenges. On the other hand, it shows them what they need to do to keep pace with international competition. This is particularly evident in the case of the digital twin: while 30 percent of companies in the DACH region still do without digital twins altogether, the figure is only 5 percent in China. There is also a considerable gap in other areas, such as automation and data analysis. The DACH region is lagging behind in terms of general data strategy and data quality in particular – a clear competitive disadvantage. Companies that do not catch up here risk being left behind in international comparison.”

Technological development is slowing down worldwide

The current barometer shows an overall value of 64 percent for the status quo of Industry 4.0. The last figure was 60 percent across all the topics surveyed, including technology, IT integration and obstacles. Although the value has increased significantly compared to previous years, it has increased more slowly than in previous years: between 2023 and 2024, for example, there was a jump from 50 to 60 percent. This means that, internationally, too, the development of technologies is progressing more slowly than before.

Focus topic: data-driven production

Although considerable progress has been made in almost all areas of Industry 4.0 in recent years, this year's results show that data analysis capabilities are increasing more slowly by comparison. This fact is addressed by this year's focus topic of data-driven production, which asks how companies can effectively use their data assets along the value chain to optimize their production.

There is motivation for increased data-driven production

Internationally, the majority of respondents perceive a data-related competitive advantage as a clear advantage: 80 percent see deep insights into core processes as a central added value, 76 percent the possibility of making decisions faster and more reliably, 74 percent the increased ability to react to the market. The motivation for increased data-driven production is therefore there.

Data as a strategic asset

Although many DACH companies have data, they do not use it sufficiently to make data-based decisions or drive innovation. Among other things, there is a lack of a holistic data strategy that targets future technologies (AI, digital twins). US and Chinese companies are more advanced in this regard: 91 percent of US companies treat data as a strategic asset, compared to 78 percent in China and 64 percent in the DACH region. “Many local companies have not arrived in the digital world, neither technically nor in terms of personnel or organization. Important tasks such as breaking down data silos, replacing legacy systems or building a scalable data infrastructure are being put off instead of being tackled with determination,” explains Dr. Johann Kranz, Professor of Business Informatics at LMU Munich. ”Unfortunately, the good economic conditions of the last decade were not used for long-term investments in more efficient production processes. In the current situation, the first thing to be cut is anything that is not essential for survival.”

Differences in the maturity of data analysis skills

There are also significant regional differences in the maturity of data analysis skills. In particular, the DACH region is significantly behind. While in the US, 78 percent of respondents rate their skills as superior to those of the competition, in the DACH region, this only applies to 61 percent. “The study results show that many companies, especially in the DACH region, need to accelerate and prioritize their digital transformation. The international comparison shows how strongly the USA and China are moving forward and consolidating their Industry 4.0 leadership positions,” says Dr. Christina Reich, professor at the FOM University of Applied Sciences for Economics & Management and manager at MHP. While these countries are benefiting from innovation-promoting regulations and targeted investments, companies in the DACH region and the United Kingdom continue to struggle with structural obstacles. Outdated IT infrastructures, a lack of skilled workers and often insufficient prioritization by management are the biggest obstacles. This is particularly evident in the automotive sector and in smaller companies.

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