Manufacturing

 Zebra Technologies Corporation has identified worker safety and real-time operational visibility as central to the evolution of manufacturing, as companies invest heavily in digital tools to strengthen frontline performance.

Findings from the company’s latest industry study, conducted in partnership with Oxford Economics, show manufacturers are allocating an average of 69% of their IT budgets to technologies that connect workers, improve asset visibility and automate workflows. These investments are increasingly being directed towards solutions that enhance safety while maintaining productivity in complex industrial environments.

A key trend highlighted in the report is the growing use of on-demand digital training tools to address workforce challenges. Manufacturers are deploying interactive kiosks, smart devices and video-based learning platforms to provide instant access to safety procedures, operational guidance and troubleshooting support. This approach allows workers to respond more effectively to risks on the shop floor, while accelerating onboarding and reducing human error.

Industry experts note that improving access to safety-critical information can significantly reduce workplace incidents, particularly in high-risk sectors. By embedding training into daily operations, companies are also aiming to close skills gaps and improve employee confidence, which can contribute to safer working conditions.

Zebra also pointed to the increasing adoption of edge computing and machine vision technologies to enhance quality control and prevent defects before they escalate into safety issues. These systems use artificial intelligence to analyse production processes in real time, identifying anomalies such as equipment faults or product inconsistencies that could pose risks if left unaddressed.

By processing data at the source, manufacturers can take immediate corrective action, limiting the likelihood of defective or unsafe products progressing along the production line. This shift from reactive to proactive quality management is helping organisations reduce waste, improve compliance and strengthen overall operational safety.

Stephan Pottel, manufacturing strategy director for EMEA at Zebra Technologies, said intelligent automation is playing a crucial role in supporting safer, more efficient factories. He noted that advanced technologies are enabling organisations to better manage labour shortages while equipping workers with the tools needed to operate in increasingly automated environments.

In parallel, traceability technologies such as RFID and machine vision are being adopted to improve transparency across supply chains. These systems allow manufacturers to track materials and components throughout production, ensuring adherence to safety and quality standards, particularly in industries such as aerospace, electronics and pharmaceuticals.

As global supply chains evolve, the integration of digital solutions is expected to remain a priority, with safety, compliance and sustainability emerging as key drivers of investment.

Emirates Global Aluminium (EGA) has been named the Advanced Manufacturing, AI and Industry 4.0 sector partner for Make it in the Emirates 2026, set to take place at ADNEC Centre Abu Dhabi from 4–7 May.

Organised by ADNEC Group, a Modon company, and hosted by the Ministry of Industry and Advanced Technology (MoIAT), alongside the Ministry of Culture, Abu Dhabi Investment Office and ADNOC, the event serves as a key platform to accelerate the UAE’s industrial growth.

It connects manufacturers, start-ups, investors and policymakers, supporting innovation and economic diversification.

EGA’s participation underscores its position as the UAE’s largest industrial company outside the oil and gas sector and highlights its contribution to advancing sustainable manufacturing.

Since its establishment in 1979, the company has evolved into a global aluminium producer with annual output exceeding 2.75 million tonnes, spanning the full value chain from alumina refining to recycling.

The company’s involvement reflects a strong focus on localisation and supply chain resilience. In 2025, EGA spent more than AED 9bn on local procurement, accounting for 42% of its total expenditure, as part of efforts to strengthen domestic industry and reduce reliance on imports.

Make it in the Emirates has also supported strategic partnerships within the metals sector. At the 2025 edition, EGA signed an agreement with China-based Sunstone to develop an anode manufacturing facility in Abu Dhabi, with construction scheduled to begin in 2026.

The partnership for the 2026 event is expected to further reinforce collaboration, innovation and investment across the UAE’s industrial landscape.

Manufacturing companies are increasingly investing in artificial intelligence to modernise IT operations, but many remain unprepared to deploy the technology at scale, according to a global survey by Riverbed.

The study, titled The Future of IT Operations in the AI Era, found that 87% of manufacturing leaders and technical specialists say their investments in AIOps – artificial intelligence for IT operations – have delivered returns that meet or exceed expectations. However, only 37% believe their organisations are fully ready to operationalise AI across the enterprise.

The findings highlight strong industry interest in using AI to streamline operations, reduce costs and manage complex global supply chains. Yet significant barriers remain. According to the survey, 62% of AI initiatives in manufacturing are still in pilot or development stages, suggesting many companies are still experimenting rather than deploying large-scale AI systems.

Data quality emerged as one of the most significant challenges. Around 90% of respondents agreed that improving the quality of organisational data is essential for AI success. However, nearly half of those surveyed reported concerns about the accuracy and completeness of their data.

In fact, 47% said they lack confidence in whether their current data can support effective AI outcomes, while only 34% rated their data as excellent in terms of relevance and usability.

Richard Tworek, chief technology officer at Riverbed, said the results illustrate both strong progress and lingering challenges within the sector.

He noted that while manufacturers are achieving positive returns from AIOps investments, many organisations are still grappling with gaps in preparedness and data quality that could slow the wider adoption of AI technologies.

Another key trend identified in the research is the growing focus on consolidating IT tools. On average, manufacturing companies currently use around 13 observability platforms sourced from nine different vendors. As a result, 95% of organisations surveyed are now working to reduce the number of tools they use in order to lower costs, improve integration and streamline IT operations.

At the same time, companies continue to evaluate new solutions. The survey found that 91% of manufacturers are considering adopting new tools to support consolidation efforts and improve interoperability across systems.

The report also highlighted the rising importance of unified communications platforms in modern manufacturing workplaces. Around 42% of employees use these tools regularly, while 66% of respondents said they are essential to day-to-day operations.

Despite this growing reliance, satisfaction remains mixed. Only 45% of respondents said they were satisfied with the performance of their communication tools, while 42% reported experiencing issues such as dropped calls, limited visibility and integration challenges.

Looking ahead, many manufacturers are prioritising stronger data infrastructure to support AI strategies. Nearly three quarters of respondents plan to establish dedicated AI data repository strategies by 2028, while network performance, data movement costs and interoperability were identified as critical factors in scaling AI applications.

The research also found widespread adoption of OpenTelemetry, with 44% of manufacturers already fully implementing the technology and a further 42% in the process of adopting it.

As manufacturers continue their digital transformation efforts, the study suggests that improving data quality, infrastructure and integration will be key to unlocking the full potential of AI-driven IT operations.

Aluminium producers in the Gulf are facing mounting supply challenges after shipping disruptions in the Strait of Hormuz and a production shutdown at a major regional smelter.

Aluminium Bahrain (Alba) has declared force majeure on some contracts after maritime activity in the Strait of Hormuz slowed significantly, according to Reuters.

The disruption follows escalating tensions in the Middle East after Iranian strikes in response to attacks by the United States and Israel affected vessels operating near the key shipping corridor between Iran and Oman.

A spokesperson for Alba said the company’s smelter operations remain unaffected, but exports have been halted because shipments cannot currently pass through the Strait.

“We are producing, but the metal is here in Alba because we are not able to ship,” the spokesperson told Reuters, adding that the declaration of force majeure is not related to any operational issues at the facility.

“Our force majeure is not due to any disruption or damage to the smelter facility,” the spokesperson said, noting that the company is working to identify alternative shipping solutions to reduce the impact on deliveries.

The Strait of Hormuz is one of the world’s most critical maritime chokepoints, carrying around one-fifth of global oil consumption and serving as a key export route for Gulf aluminium producers.

Industry estimates suggest that more than five million tonnes of aluminium are shipped through the passage each year by smelters in Bahrain, Qatar, Saudi Arabia and the United Arab Emirates.

At the same time, production has been disrupted at Qatalum, a joint venture involving Norsk Hydro. The company has begun a controlled shutdown of its aluminium production after a shortage of natural gas in Qatar linked to the regional conflict.

The shutdown process started on 3 March and is expected to be completed by the end of the month. The decision followed a notification from QatarEnergy that gas supplies to the smelter would be suspended.

Qatalum said the controlled shutdown aims to reduce health, environmental and safety risks associated with halting production while preparing the plant for a possible restart.

However, a full restart could take between six and 12 months, and it remains unclear when the facility might resume operations if the shutdown continues.

Hydro said it is assessing options to mitigate the impact and exploring alternative ways to meet contractual obligations. The company has also issued a force majeure notice to Qatalum customers following the production halt.