Cognizant: The Top Five Manufacturing AI Trends for 2025

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Prasanth Thomas, Head of UKI Consulting for Manufacturing, Logistics, Energy & Utilities at Cognizant
Prasanth Thomas, UKI Consulting Head for Manufacturing, Logistics, Energy and Utilities at Cognizant, shares which five AI trends will shape manufacturing

AI is transforming the manufacturing industry, rapidly becoming an integral part of operations.

As 2025 gets fully under way, Prasanth Thomas, UKI Consulting Head for Manufacturing, Logistics, Energy and Utilities at Cognizant, shares his insights on the future of AI.

Below are his thoughts on the top five AI trends manufacturers can expect to see this year.

1. AI will drive smarter problem-solving and decision-making

Prasanth notes that AI is not a new concept within manufacturing, as it has already been employed to enhance various parts of the production process, like forecasting demand and optimising inventory levels. However, manufacturers are now expanding its use into more areas of their organisations.

Initially limited to basic tasks such as monitoring, reporting, and isolated use cases, AI is now being used for more advanced problem-solving and decision-making. For example, AI can help manufacturers predict supply chain disruptions by simulating potential risks based on real-time data, enabling proactive mitigation of those disruptions.

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2. Generative AI will make technology more user-friendly

Prasanth explains that, while traditional AI supports shop floor operations, generative AI is the technology that will enable workers to better access its benefits. Gen AI can transform large data sets into interactive, user-friendly visuals, making it easier for employees to interpret information.

By adding an engagement layer on top of various systems and AI models, Gen AI can simplify technical complexities for workers. This, in turn, will empower employees to make more informed decisions and improve processes such as predictive maintenance and quality control.

3. Evolving required skillsets will transform job roles

Prasanth points out that AI is increasingly taking over the mundane tasks on which workers spend a lot of time, freeing them to focus on higher-value, strategic activities.

As this shift continues, job roles in manufacturing will evolve, with employees needing skills that enable them to collaborate effectively with emerging technologies. While workers won’t need to become data scientists, they will need to understand how to work with data and use AI to solve problems.

4. Generative AI will boost sustainability efforts

Prasanth highlights that sustainability has become a crucial issue for both regulators and consumers, with businesses being held accountable for the sustainability of their entire supply chains.

Many manufacturers will need to demonstrate strong sustainability credentials to retain and attract business. As sustainability reporting becomes increasingly important, it can also be resource-intensive.

Gen AI has the potential to simplify and streamline this process by automating complex, data-heavy reporting tasks. It can also run simulations to compare the sustainability impact of different scenarios, allowing manufacturers to better track, report and showcase their sustainability efforts to meet growing expectations.

Generative AI is reshaping manufacturing

5. Data will take centre stage as demand for servitisation grows

Prasanth explains that, traditionally, manufacturing focused on production efficiency and quality control, often at the expense of customer engagement.

However, as manufacturers shift towards a servitisation model – offering ongoing services throughout a product’s lifecycle rather than simply selling a standalone product – there will be an increased need to analyse product usage and performance data.

AI will help manufacturers generate new revenue streams by providing additional services such as maintenance and predictive analytics, keeping customers engaged long after the initial product has left the factory.

The road ahead

Looking towards 2025, Prasanth emphasises that AI will continue to reshape the manufacturing landscape, driving smarter decision-making, supporting employees in their day-to-day work, and enhancing sustainability efforts.

As job roles evolve and the servitisation model gains traction, AI will play an increasingly central role.

The potential for AI to transform manufacturing is vast, and those manufacturers who can quickly adapt to these trends will be better positioned to remain competitive and resilient in a rapidly-changing industry.

Cognizant is one of those that will continue to provide the software, support and insights to help manufacturers do so.


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