Report

The United States Factory Automation And Industrial Controls Market size is estimated at USD 0 billion in 2025, and is expected to reach USD 0 billion by 2030, at a CAGR of 7.80% during the forecast period (2025-2030).

Key Highlights
- Driven by the quest for heightened efficiency, precision, and cost-effectiveness, the U.S. has witnessed a pronounced uptick in factory automation demand. As industries pivot towards digital transformation, automation technologies-spanning robotics, artificial intelligence (AI), and the Industrial Internet of Things (IIoT)-are cementing their roles in contemporary production lines.
- Labor shortages, escalating production costs, and a relentless pursuit of superior quality and output fuel this rapid expansion. From automotive and electronics to food processing and pharmaceuticals, companies across diverse sectors are making substantial investments in automation to maintain their competitive edge in the U.S. market.
- Technological strides have been pivotal in propelling factory automation in the U.S., revolutionizing manufacturing processes and bolstering efficiency, productivity, and quality. By harnessing state-of-the-art technologies-like robotics, AI, machine learning, IIoT, and digital twins-companies are fine-tuning production, slashing costs, and staying ahead in a swiftly changing global arena. As the industry pivots towards smart manufacturing, the embrace of these innovations is not only refining the factory landscape but also making automation increasingly sophisticated and accessible.
- Moreover, buoyed by proactive government initiatives and a vibrant startup scene, the U.S. factory automation market is witnessing notable strides. With manufacturers under pressure to boost efficiency, curtail costs, and fortify supply chain resilience, automation emerges as a pivotal solution.
- Recognizing the strategic weight of advanced manufacturing, the federal government has rolled out a suite of policies and incentives to hasten automation's adoption. Concurrently, a dynamic startup ecosystem is pioneering advancements, crafting state-of-the-art solutions in robotics, AI, and IIoT. Collectively, these elements are reshaping the U.S. manufacturing landscape, rendering automation not just essential but also more attainable.


US Factory Automation and Industrial Controls Market Trends

Distributed Control Systems (DCS) are Expected to Witness Significant Adoption


- A Distributed Control System (DCS) automates control in industrial processes, adeptly managing complex, large-scale operations. Multiple controllers, spread across a facility, communicate via a central network, ensuring precise and coordinated control. Industries like oil & gas, power generation, chemicals, pharmaceuticals, and food & beverage predominantly utilize DCS, especially in continuous and batch processes.
- The U.S. is witnessing a surge in industrial robotics adoption, propelling the country's factory automation market. For instance, a report from the International Federation of Robotics highlights significant investments by U.S. manufacturing firms in automation. In 2023, industrial robot installations surged by 12%, totaling an impressive 44,303 units.
- As industrial robots become more prevalent in U.S. manufacturing, the demand for DCS is rising. DCS enables robots to operate within a defined three-dimensional (3D) workspace. This software allows designers and programmers to delineate the robot's operational space, optimizing the area designated for the robot cell. In response to this growing demand, companies are increasingly adopting automation technologies, with the DCS segment gaining significant traction.
- The industry is shifting towards more integrated and intelligent control systems. With Industry 4.0's emphasis on connectivity, automation, machine learning, and real-time analytics, DCS platforms are evolving. These upgrades promise enhanced process optimization, predictive maintenance, and superior decision-making.
- Companies are pouring investments into digital technologies to boost operational efficiency. Digital twins, or virtual replicas of physical assets, are now being paired with DCS. This synergy aids in simulating, predicting, and optimizing industrial processes, facilitating real-time monitoring, and control, thereby minimizing downtime and amplifying productivity.
- Major market players are bolstering their DCS offerings, enhancing support for clients transitioning from third-party control systems. For instance, in November 2024, Emerson Electric Co enriched its DeltaV Automation Platform with the DeltaV Version 15 Feature Pack 2 update. This update simplifies transitions from third-party systems to DeltaV DCS, broadens support for data-centric Ethernet networks, and streamlines state-based control implementations.


Automotive and Transportation Industry is Expected to Exhibit Significant Adoption


- As industries across the United States increasingly embrace Industry 4.0 and smart manufacturing, they are witnessing a notable uptick in sales. A 2023 report from BAE reveals that the U.S. automotive sector sold roughly 15.5 million light vehicles. This figure encompasses about 3.12 million passenger cars and close to 12.4 million light trucks sold at retail. Such a surge underscores the escalating appetite for vehicles in the U.S. market.
- Duration of projects stands as a pivotal concern for the automotive industry. This concern has spurred a heightened demand for factory automation systems, encompassing industrial control systems and field devices. These tools facilitate enhanced customization and innovation in automotive manufacturing. Take automated assembly lines, for example: they serve as the backbone of contemporary automotive production. Robots, with their unparalleled speed and precision, handle tasks like welding, bolting, and material management. This automation not only trims down the time taken to assemble a vehicle but also boosts overall production throughput.
- Furthermore, The transportation sector is playing a crucial role in accelerating the adoption of factory automation. Efficient logistics and supply chain management are essential for manufacturing success, and as transportation networks evolve, factories must adapt to keep pace. Looking at the growing demand there has been several new launches in the country that is driving the overall market significantly. For instance, Benteler EV Systems, Beep Inc., and Mobileye, an Intel subsidiary, have announced a strategic partnership to design and deploy automotive-grade, fully electric autonomous shuttles across public and private sectors in North America. Focused on addressing first- and last-mile urban transportation needs, these shuttles are scheduled to commence production deployments in the United States in 2024.
- The collaboration between manufacturers, transportation providers, and technology companies is fostering innovation in factory automation. Leading companies in robotics, AI, and industrial IoT are working closely with logistics firms and supply chain managers to develop integrated solutions that enhance efficiency across the production and distribution chain. Cloud-based platforms, digital twins, and real-time analytics are enabling seamless communication between factory automation systems and transportation networks, ensuring a synchronized and agile approach to manufacturing and logistics.


US Factory Automation and Industrial Controls Industry Overview

The United States factory automation and industrial controls market is competitive due to several players such as Schneider Electric SE, Rockwell Automation Inc., Honeywell International Inc., Emerson Electric Company, and ABB Ltd. in the market. Players are involved in product development and strategic activities such as partnerships, mergers, and acquisitions.

One of the most prominent trends shaping the future of factory automation is the increasing use of robotics and automation solutions. Robotics are becoming more advanced and versatile, allowing manufacturers to automate a wider range of tasks and processes. This not only enhances productivity and efficiency but also reduces the reliance on manual labor, addressing the skilled labor shortage that many industries face. Additionally, the integration of AI and IoT technologies enables real-time data monitoring and analysis, leading to more informed decision-making and optimized operations.

Another significant trend is the shift towards modular and scalable automation systems. These systems allow manufacturers to easily integrate new technologies and expand their automation capabilities as needed. This flexibility is crucial for industries that are rapidly evolving and require continuous innovation to stay competitive. Furthermore, the adoption of cloud computing and edge computing technologies is transforming the factory automation landscape. Cloud-based solutions offer remote monitoring and control, while edge computing enables real-time data processing at the source, enhancing responsiveness and agility.

Additional Benefits:

- The market estimate (ME) sheet in Excel format
- 3 months of analyst support