Digital transformation was supposed to be an efficient evolution. But for most manufacturers and energy leaders, ROI is threatened by the gap between smart systems and everyday human performance on the shop floor.
The costly reality everyone sees but rarely discuss
Billions are invested in digital twins, XR, and smart assets each year. Yet 68% of manufacturers report that their pilots stall, not because of the tech, but because frontline teams and processes can’t keep pace. Downtime, compliance surprises, and missed targets remain stubborn and expensive headwinds.
What’s driving this gap?
Onboarding still takes too long and training fails to stick.
Ongoing training isn’t keeping up with plant complexity, safety standards, or regulatory change.
Most digital investments outpace the muscle memory and confidence of the people using them.
The numbers behind the challenge
Challenge | Metrics |
|---|---|
Faster feedback | $50B lost annually (Industry Data) |
Stalled pilots | 68% fail due to people/process gaps (Deloitte) |
Incomplete integration | Only 1 in 5 reach full deployment (PEN, 2025) |
What does the industrial frontline need to improve resilience?
Industrial winners think differently. For them, it’s not about more technology. It’s about closing the “human-tech gap” with hands-on, real-world enablement that actually sticks.
They prioritize upskilling and scenario practice as part of daily workflows, not just periodic events.
They give teams tools to test and prove readiness before mistakes, not after.
They treat compliance and safety as lived, everyday habits, baked right into routine.
Understand the huge costs of workforce gaps and the benchmarks being set by leaders who are closing them.
Use this infographic to learn how to move beyond pilots toward a truly scalable, resilient, and audit-ready digital operation.
Set a new standard: Make tomorrow work.
Explore where your organization stands on the human-tech curve and learn how to move confidently forward with CGS Immersive.