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From pilot to progress: turning digital manufacturing projects into real impact 

Digital transformation remains a top priority for manufacturers, yet many struggle to move beyond the pilot phase – often falling into what is commonly called ‘pilot purgatory’. In a recent interview, Sergey Konstantinov of Samworth Bros shared practical insights into how organisations can successfully scale their digital initiatives.

A key challenge, Sergey explains, is an overemphasis on technology.

““Most projects get stuck in ‘pilot purgatory’ because businesses focus on the ‘how’ before clearly defining the ‘why’ and the KPIs that matter.”

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While new tools and platforms generate excitement, they are rarely the root of success. Instead, manufacturers must start by clearly defining the ‘what’ and ‘why’ of their projects. This means identifying the specific business or operational problem to solve and aligning it with measurable KPIs from the outset. Without this clarity, even the most advanced technologies risk delivering limited value.

Equally critical is the human factor. Digital transformation is fundamentally about people, not just systems. Engaging key stakeholders early – especially those working on the shop floor – ensures solutions are practical, relevant and widely adopted. Building a collaborative team and fostering a sense of ownership can significantly improve the chances of scaling beyond pilot stages.

Change management also plays a decisive role. Organisations must develop structured plans for how new technologies will be introduced, adopted and sustained. This includes clear communication, training and ongoing support to embed changes into daily operations.

Looking ahead, AI is set to further transform manufacturing. Generative AI is already supporting operators through improved work instructions, reporting and problem-solving. Meanwhile, agentic AI is evolving toward autonomous decision-making – monitoring processes, predicting maintenance needs, and even initiating actions such as ordering parts or scheduling repairs.

Despite these advancements, Sergey emphasised that human oversight remains essential. While AI can enhance efficiency and decision-making, the final responsibility still lies with skilled operators. Ultimately, successful digital transformation will depend on aligning technology, people and strategy into a cohesive, scalable approach.

Sergey Konstantinov

Automation Project Manager, Samworth Brothers