
ifaa study: Artificial intelligence in manufacturing companies
About the study
The aim of the 2022 study was to assess the current state of AI implementation in manufacturing companies and the resulting opportunities and challenges. With a focus on formulating recommendations for practical implementation, the study identified critical success factors for the use of AI.
The sample included 459 participants from all sectors and functional areas of manufacturing (NACE code 2008), with the metal and electrical industry accounting for 59 percent, and manufacturing operations being the most frequently cited area of activity at 27 percent. 46 percent of participants were from small and medium-sized enterprises, while 26 percent were from companies with more than 1000 employees. Nearly half (44 percent) of the respondents stated that they did not hold any managerial responsibilities.
Angebotstyp
Larger companies are proving to be pioneers in the practical implementation of AI. Compared to small and medium-sized enterprises, larger companies are increasingly using or planning to use AI. 50% of the study participants from companies with more than 1000 employees indicate that AI is already being used in their organization, with an additional 38% of this subgroup confirming plans for AI implementation. In contrast, 65% of the study participants working in microenterprises with fewer than 50 employees state that AI is neither being used nor planned for use.

First results of the ifaa study "Artificial intelligence in manufacturing companies"
- Significance of AI
The respondents were asked to assess the significance of AI for their company. The analysis revealed a noticeable split in opinions. A 33 percent share was allocated to those who attribute either a minimal or a significant importance to AI. Just one percent more accounted for respondents who were uncertain about the importance and answered "Mixed feelings."
- AI in the company?
When asked whether artificial intelligence is already being used in the company, 36 percent of the respondents stated that this is already the case. Another 37 percent indicated that artificial intelligence is at least in the planning stages, while only 27 percent denied any planning. Further breakdown of the number of applications among those who affirmed the introduction of AI revealed that 82 percent have implemented at least 2 applications.
- Securing skilled labor
66% of the respondents from companies where AI has been introduced or is planned (fully) agree that AI helps to counteract skilled labor shortages. Significant potential is seen in increasing productivity and efficiency of processes (approximately 71% agreement). 54% of the respondents believe that the introduction of AI enhances job roles. Among these, 57% are of the opinion that AI helps employees focus on more interesting tasks. 53% see the potential for preserving employees' knowledge.
- Functional areas
The respondents from the subgroup (AI introduced or planned; N=332) were asked to allocate the planned or implemented AI application to a functional area within their company. Given that manufacturing is the most represented area in the sample, it is not surprising that it also ranks highest in the allocation of planned or introduced AI applications, at 56 percent. The second most frequently mentioned area was Logistics & Warehousing, with 34 percent, followed by Assembly at 26 percent. Conversely, only a small 4 percent mentioned the area of Corporate Management.
- AI Technologies
Regarding the technologies used in planned or implemented AI applications, image and sound processing, as well as multidimensional pattern recognition, were mentioned most frequently, at 39 percent. Close behind was text and speech processing at 37 percent, followed closely by action planning and optimization at 35 percent. The area of knowledge representation and semantics was mentioned much less frequently, at 27 percent, and even further behind was emotion recognition and intent analysis, mentioned by just 9 percent.
- Potential of AI
Furthermore, respondents from the overall sample were asked for a general assessment of the AI potential for the specified business areas. Manufacturing was attributed the greatest potential, followed closely by logistics & warehousing, and shortly thereafter, assembly. Company management was seen to have the least potential in this regard.
- Use of AI
Regarding the beneficial changes for companies that the introduction of artificial intelligence could bring, most respondents agreed on the reduction of personnel costs and the shortening of processing and lead times. There was some indecision, however, regarding whether AI can contribute to the enhancement of job roles or the improvement of decision-making ability.
- Concerns
When asked, "How concerning do you find the use of AI in general?" 40 percent of all respondents (N=459) answered with concerning or very concerning. Only 33 percent of the study participants consider the use of AI as (completely) unproblematic. The high proportion of the "neither/nor" response option illustrates the uncertainty in answering the question.
- Trust
When asked which trust factors are considered essential regarding artificial intelligence, nearly 50 percent of respondents stated that human supervision and control are most important. Another relevant point is the reliability and freedom from manipulation of AI systems, as well as the protection of personal data. Only 22 percent of respondents considered the possibility of intervention by works councils and employee representatives essential for their trust.
- Competencies
Leadership requires competencies for the successful implementation of artificial intelligence. They need expertise in technical, social, methodological, and self-competencies. In the context of the ifaa study, the 459 participants rated AI technical competencies as the most important for shaping the digital transformation process, followed by social and methodological competencies. According to the 459 participants, leadership self-competencies rank fourth.
- Leadership
Leaders play a crucial role in the introduction of artificial intelligence. 50% of the 459 participants attest to leaders playing a very important role in the successful implementation of AI. Overall, 91% of participants consider the role of leaders as very or somewhat important.
To successfully shape the entire digital transformation process, leaders need important personality traits. In the ifaa study, the 459 participants had the opportunity to select the most important personality traits in a multiple-choice format. Individual willingness to change was chosen by 131 out of 459 participants as the top-ranked trait. Furthermore, 81 out of 459 participants indicated that they see enthusiasm as second-ranked. On the other hand, 112 out of 459 participants ranked leaders' curiosity as seventh and last.
- Barriers to AI Implementation
According to the assessment of the 332 respondents, the lack of AI expertise in companies is considered a significant obstacle (44 percent) to a very significant one (16 percent). This is followed by the factor of "employees' fears of AI." Here, 39 percent consider this a major obstacle, and 13 percent even consider it a very significant one. Other significant obstacles, according to the respondents, may include high costs and data protection requirements. However, more than 50 percent of respondents consider the lack of availability of good algorithms and data to be a minor or no obstacle.
- Effects on Employees
66 percent of the 449 respondents estimate that the use of AI demonstrates how innovative companies are positioned, which in turn increases the attractiveness of the workplace for professionals. 45 percent believe that AI even increases employee motivation, and 58 percent believe that it increases learning opportunities. 53 percent of respondents believe that AI helps reduce the complexity of tasks.
Get in touch with us!

Dr.-Ing.
Markus Harlacher
Wissenschaftlicher Mitarbeiter
Telefon: +49 2233 600371-3

Dipl.-Soz. Wiss.
Nicole Ottersböck
Wissenschaftliche Mitarbeiterin
Telefon: +49 211 542263-25