How ABB Automation Extended Supports Manufacturing Upgrades

Manufacturers can now access a modern pathway to system advancement through ABB's Automation Extended programme, which offers a strategic approach to technological evolution.

The programme is built on ABB's established platforms and protects current investments whilst delivering a contemporary automation ecosystem designed for advanced analytics, AI and IoT integration.

According to ABB, the programme enables technologies to be adopted at the pace that suits individual customers without introducing operational risk.

Evolving control systems

The Automation Extended programme is an evolution of ABB's distributed control systems, created to support industries in modernising their operations without causing disruption.

The company explains: “Building on ABB’s long-standing leadership with the world’s largest DCS installed base and vision in process automation, Automation Extended outlines how future automation capabilities can be introduced progressively.

“It preserves system integrity while enabling the flexibility, scalability and efficiency needed for the next era of industrial operations.”

Peter Terwiesch, President, ABB’s Automation business area, says: “In industries we serve – many operating large and complex infrastructures that deliver essential resources – our customers rely on modernisation without disruption.

“Automation Extended delivers exactly that: bringing future-ready capabilities into the systems they know and trust, with security and interoperability at the core.”

Responding to industry challenges

The programme arrives at a time when industrial operations face demanding circumstances, including volatile markets, cybersecurity challenges, regulatory pressures and a rapidly evolving workforce.

ABB says the tool responds to these realities by enabling innovation with agility and pace without disrupting production, supporting advanced analytics and IoT integration and simplifying operations for diverse skill levels.

Automation Extended could support manufacturers to further enhance resilience and growth in safety, productivity and sustainability.

The programme is designed to pave the road towards autonomy, utilising AI technologies and directly responding to the industry's requirements to retain, share and augment workforce knowledge.

ABB says the system could also fuel the energy transition and enable remote operations whilst providing operators with an immersive experience and contextualised information and support, aiming to ensure operator effectiveness and optimal plant productivity and reliability.

Technology transformations

Deloitte's 2026 Manufacturing Industry Outlook says that the industry is moving from experimental AI pilots to at-scale implementation.

Success, it says, depends on balancing aggressive technology investment with highly adaptive workforce strategy. 

A 2025 Deloitte survey of 600 manufacturing executives found that 80% plan to invest 20% or more of their improvement budgets in smart manufacturing initiatives. 

These investments will focus on foundational tools and technologies including automation hardware, data analytics, sensors and cloud computing.