By Keirsten Deegan, AIA | Principal, Industrial Manufacturing Practice Leader
Industrial manufacturing is ever-evolving, and despite labor shortages, continued supply chain disruptions and fluctuating demand, the industry is on the up and up. To handle demand, companies are making a generational shift from machine-based assembly lines to “smart factories.” Architects and designers must adapt their design of these crucial facilities as new production methods, sustainable initiatives, and recruitment tactics become paramount.

Understanding Industrial Manufacturing
As an award-winning architectural firm, Ci focuses on various industrial manufacturing facilities including heavy and light manufacturing, distribution and e-commerce, food and beverage, and controlled environment agriculture. These projects play essential roles in the products produced, stored and delivered to consumers every day. Our approach emphasizes maximizing operational efficiency, optimizing space utilization and ensuring the design is adaptable to evolving industry needs.
Reshoring
A renaissance in reshoring is underway as US industrial policies favor domestic manufacturing. The 2021 Bipartisan Infrastructure Law, the 2022 CHIPS and Science Act, and the 2022 Inflation Reduction Act have encouraged the production of US-made products, and in turn, the construction of manufacturing facilities has experienced a dramatic rise. Last year, Ci completed the design and construction of the largest solid-state battery assembly line in the US for Factorial Energy to commercialize its electric vehicle technology. The $50 million investment created 150 new jobs in Massachusetts and represents an impressive step in onshoring battery manufacturing.

Going Smart
Artificial intelligence and machine learning are revolutionizing several industries, and industrial manufacturing is no exception. As older equipment continues to be phased out, new digital technologies are helping manufacturers become more efficient by enabling remote monitoring, servicing and equipment operation – all without the need to be on-site. Virtual operation makes it seem like the operator is in the room with the machine, which increases access, flexibility and safety in production. Communications and data analytics become more accurate and effective as these new methods drive predictive maintenance, reduce unplanned downtime and create material cost savings. According to a recent study by Deloitte, 83% of manufacturers believe that smart factory solutions will transform the way products are made in five years.
Reducing Carbon Footprints
States like Massachusetts are unveiling clean energy and climate plans to target net-zero greenhouse gas emissions in the next few decades. As the call to action for sustainable practices continues, industrial manufacturers are making strides to reduce carbon emissions, as almost a quarter of US greenhouse gas emissions come from industrial sources. Low carbon and renewable energy resources, such as hydrogen, are being introduced to align with clean energy goals. Electric vehicles for the transport of raw materials can take advantage of clean vehicle tax credits and save on energy usage costs. In addition to sustainability requirements for government, municipal, and institutional contracts, manufacturers can expect to see more stringent guidelines from commercial customers as well.
Targeting Recruitment
Labor shortages facing US industrial manufacturers are expected to worsen in the coming years as workers change industries, retire faster than they can be replaced, and struggle to keep up with new technical skills. The National Association of Manufacturers (NAM) conducted a survey that found almost three-quarters of surveyed manufacturing executives feel that attracting and retaining a quality workforce is their primary business challenge.
Companies must introduce new initiatives, such as enhanced amenities and digital learning tools, to keep up with a highly competitive labor market. Locating industrial plants near major highways, intersections, waterways and ports is essential for the transportation of goods, but companies must also consider proximity to universities with manufacturing certification programs for more opportunities to hire young talent. Adapting to the latest changes in the industry will be crucial for industrial manufacturers to thrive.