Tackling Manufacturing Digital Transformation Challenges – Reflections from PDSForum Event

Last week, I attended the PDSForum at the Manufacturing Technology Centre (MTC), where manufacturing leaders tackled key engineering and manufacturing digital transformation challenges. From data trust to sustainability, the discussions weren’t just about technology—they were about solving real-world problems that every leader faces on their journey.

Yet, what struck me most wasn’t the tech on display but the recurring themes that every manufacturing leader should pay attention to. From foundational challenges like data trust to visionary takes on sustainability, this event served as a powerful reminder: digital transformation is about more than tools. It’s about people, strategy, and execution.

Here are the key takeaways that resonated most.

Start simple, but start somewhere.

Transformation isn’t about diving headfirst into the latest technology. As Russell Rickett from Teledyne e2V shared, sometimes the simplest wins can deliver the most value. Over 25 years, Teledyne e2V evolved from basic data management systems to an enterprise-level PLM approach.  As someone who began my career in radiotherapy technology, hearing how Teledyne’s innovations impact cancer treatment every 0.25 seconds was both humbling and energizing. It underscores the critical role that even the smallest advancements in design and simulation tools play in creating a better future.

The secret? Progress at the right pace. Rather than rushing into new processes or tools, they built foundational systems early, ensuring buy-in from their teams. Russell also highlighted a key challenge: suppliers and customers often don’t adopt new systems at the same speed, meaning a staggered, deliberate approach can often be the wisest.

💡 Key takeaway for leaders: Before leaping into big, complex solutions, focus on smaller improvements that deliver immediate, tangible benefits. It builds momentum—and trust.

Without trusted data, digital dreams fail.

Paul Haimes put it bluntly: you can’t unlock the potential of AI, digital twins, or predictive modelling without a bedrock of reliable data. He painted a compelling picture of what’s possible when data trust exists, pointing to Tesla’s Optimus robot and Rolls-Royce’s “Power by the Hour” service model.

But chasing “big tech” dreams without trusted data is like trying to build a skyscraper on quicksand. Paul also outlined five drivers of digital transformation—workforce shifts, supply chain collaboration, increasing software complexity, sustainability, and service optimisation. Together, they form a framework for leaders to think strategically about their priorities. His insights reinforced a principle I hold dear: before chasing buzzwords, get the basics right.

💡 Key takeaway for leaders: Before anything else, invest in your data. How confident are you in its accuracy, consistency, and accessibility?

Agility is the new competitive advantage.

Nathan Bailey from Advanced Innovation Engineering (AIE) shared an inspiring case study on how smaller companies can punch above their weight. With tools like 3D printing and advanced simulation, AIE has cut design cycles dramatically and responded to challenges faster than their larger competitors.

But it wasn’t just the technology that made this possible. AIE’s success comes from a combination of agility, focus, and clarity of vision—traits that allow them to adapt swiftly while staying outcome-driven.

💡 Key takeaway for leaders: Technology accelerates agility, but the real driver is an organisation’s mindset. Is your company structured to respond quickly and effectively to change?

Sustainability isn’t an afterthought—it’s the foundation.

Will Marsden of Ansys delivered a standout session on how sustainability is transforming engineering design. Using AI-driven simulation, Ansys is enabling companies to iterate billions of design permutations to balance cost, performance, and environmental impact.

One powerful example? An aircraft wing optimised to reduce carbon emissions while maintaining structural integrity, cost and mass. This isn’t just a “nice to have.” It’s a necessary shift toward circular design—where products are created with their full lifecycle in mind, from initial build to eventual reuse or recycling.

💡 Key takeaway for leaders: Sustainability isn’t a compliance exercise. It’s the cornerstone of future design strategies. How sustainable are the products you’re creating today?

Building tomorrow’s talent starts now.

One of the most exciting stories came from Scalextric4Schools, a project inspiring students with hands-on experience in 3D printing, CAD, and full product lifecycle management. While the initiative is making strides, only 30% of participants are female—a stark reminder of the need for greater diversity in engineering.

For manufacturers, engaging with projects like this isn’t just an act of goodwill; it’s a strategic imperative. The digital tools and challenges of tomorrow require a diverse, prepared, and inspired workforce.

💡 Key takeaway for leaders: What is your business doing to support the next generation of engineers? The future workforce needs to be built today.

The essentials of transformation: vision, data, and people.

Throughout the forum, one theme remained constant: success isn’t just about adopting new tools; it’s about aligning those tools with a clear vision, strong processes, and a focus on people.

Olive Warren from Watson Marlow illustrated this beautifully with his account of simplifying product configuration processes and integrating them into ERP systems. It wasn’t a flashy transformation, but it was transformational for their business. Trusted data and clear planning underpinned their progress—a reminder that change starts with the basics.

💡 Key takeaway for leaders: A clear vision and engaged teams make transformation possible. How well does your organisation connect its strategy with its execution?

Final thought: How will you start your next chapter?

The lessons from the PDSForum aren’t theoretical—they’re actionable. Whether you’re grappling with outdated systems or chasing digital twins, the fundamentals remain the same:

• Start small and build momentum.
• Focus on data integrity and trust.
• Stay agile and aligned with clear goals.
• Embed sustainability into your strategy.
• Invest in people—your current teams and the next generation.

Manufacturing is evolving fast, but every transformation begins with a single step. What’s yours going to be?

💬 Let’s discuss—what’s the one insight from your transformation journey that others could learn from? Share your thoughts below!

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