Bridging Labor Gaps with Automation and Workforce Upskilling

Labor shortages continue to challenge U.S. manufacturers in 2025. From retiring baby boomers to a lack of younger workers entering the trades, factories are under pressure to maintain output while dealing with fewer hands on the floor. Instead of slowing down, many companies are accelerating two parallel strategies: adopting automation technologies and retraining their workforce to thrive alongside them.

This approach isn’t about replacing people—it’s about redefining roles, boosting efficiency, and giving workers the tools to stay competitive in an evolving industry.

Why Labor Shortages Are Reshaping Manufacturing

Workforce constraints are hitting nearly every segment of industry. Skilled machinists, technicians, and maintenance personnel are in short supply. According to Deloitte, U.S. manufacturers could face over 2 million unfilled jobs by 2030 if the gap continues to grow.

The result? Production delays, missed orders, and higher costs. Manufacturers can’t afford to wait for a new generation of workers to fill the pipeline—they’re turning to automation as a force multiplier.

Automation as a Force Multiplier

Advanced robotics, collaborative robots (cobots), and smart drives and controllers are filling critical gaps. Automation doesn’t call in sick, and it can take on repetitive, dangerous, or high-precision tasks at scale. This not only stabilizes output but also allows companies to redeploy human workers toward higher-value roles such as system monitoring, programming, and maintenance.

Recent industry talks, like those highlighted in TIME’s Industrial Renaissance discussion, emphasize that the future is not “machines versus people” but machines plus people—an integrated workforce where technology enhances human potential rather than replaces it.

The Rise of Workforce Upskilling

Forward-thinking manufacturers know automation alone is not enough. The biggest returns come when human expertise is combined with automated systems. That’s why many companies are investing in:

• Technical training programs to teach workers how to program PLCs, troubleshoot drives, and work with robotics.

• Partnerships with trade schools and community colleges to build a pipeline of automation-ready talent.

• On-the-job cross-training so workers can move fluidly between machine operation, maintenance, and digital monitoring roles.

By retraining employees to work alongside machines, manufacturers retain institutional knowledge, keep loyal staff engaged, and minimize turnover.

Real-World Impact on the Factory Floor

Factories that adopt this dual approach see clear benefits:

• Reduced downtime thanks to skilled employees who can troubleshoot both mechanical and digital issues.

• Improved safety as automation takes on hazardous tasks while humans oversee system performance.

• Higher morale when workers feel they’re gaining valuable skills instead of being displaced.

• Increased output and flexibility as teams combine the speed of automation with the adaptability of people.

For example, plants that implemented cobots to handle material handling or assembly found they could scale production without adding more shifts—while reskilled workers shifted into supervisory or technical support roles.

How to Get Started

If you’re navigating labor gaps in your plant, consider these steps:

1. Assess your processes – Identify where automation could deliver the biggest impact (e.g., repetitive tasks, bottlenecks, or dangerous operations).

2. Invest in flexible automation – Modular drives, PLCs, and cobots allow scaling without major overhauls.

3. Create a training plan – Work with vendors, local colleges, or in-house specialists to build up employee skills.

4. Communicate the vision – Help employees see automation as an opportunity for career growth, not a threat.

Building a Future-Ready Workforce

The factories thriving in 2025 aren’t just adopting robots and smart drives—they’re building cultures of adaptability. Automation addresses the labor shortage, but it’s workforce upskilling that ensures people remain central to the equation.

The future of manufacturing isn’t about fewer people—it’s about more capable people, empowered by technology.