How software-defined manufacturing can revolutionise production

By Mark Patrick, Director of Technical Content, EMEA, Mouser Electronics

SDM replaces traditional hardware-based systems with software-driven processes that enable manufacturers to create highly adaptable and flexible production environments. This approach allows manufacturers to respond rapidly to market changes, optimise real-time processes, and significantly improve operational efficiency. Electronics engineers are at the forefront of this shift, working tirelessly to develop and deploy hardware and software systems that make SDM a reality. Their efforts span the integration of programmable logic controllers (PLCs), Internet of Things (IoT)-based monitoring systems, and industrial computing platforms that drive flexibility, real-time process optimisation, predictive maintenance, and remote diagnostics.

This article examines how SDM is reshaping the manufacturing sector, focusing on the critical role that electronics engineers play in developing hardware and software components. We will explore key technologies, such as programmable logic controllers (PLCs) and IoT monitoring systems, that enable SDM to operate at its full potential. Additionally, we will highlight specific products that are integral to the successful implementation of SDM in modern manufacturing environments.

The power of software

SDM is a paradigm shift in production systems, where software controls the manufacturing process rather than relying on rigid, hardware-based systems. Traditional manufacturing systems are typically inflexible and require significant time and effort to reconfigure when changes are needed. In contrast, SDM allows manufacturers to adjust production lines quickly by controlling them through software, which communicates with hardware components via programmable interfaces. This flexibility is especially important in today’s fast-moving marketplace, where companies must stay agile and responsive to consumer demand and industry trends.

At its core, SDM offers several compelling advantages over traditional manufacturing methods. One key benefit is enhanced production flexibility. Unlike traditional production lines, which are often constrained by fixed hardware configurations, SDM allows manufacturers to modify production processes swiftly and with minimal downtime. This means that a manufacturing line can be reprogrammed to produce a different product, adjust production rates, or accommodate new materials without the need for significant retooling or hardware changes (Figure 1).

Figure 1: Software-driven production lines revolutionise the manufacturing process, enabling real-time optimisation and unmatched flexibility in modem industry (Source: DigitalDruid/stock.adobe.com)

Another significant advantage of SDM is real-time process optimisation. In SDM environments, sensors and data analytics continuously monitor production processes, providing real-time insights into performance metrics. This data can then be used to make immediate adjustments to improve production efficiency, product quality, and resource utilisation. By leveraging this data, manufacturers can identify inefficiencies, reduce waste, and ensure optimal resource allocation.

Predictive maintenance is another critical component of SDM that can drastically reduce unplanned downtime. By using IoT-based monitoring systems, SDM enables manufacturers to track the health of machinery and predict when maintenance is needed before a failure occurs. This proactive approach ensures that equipment is kept in optimal condition, preventing costly breakdowns and production halts.

Lastly, SDM facilitates remote diagnostics, allowing engineers and operators to access production data anywhere. This capability is especially valuable when troubleshooting or diagnosing equipment issues, as it eliminates the need for on-site visits and reduces the time it takes to identify and resolve problems.

Building the backbone of SDM: key systems and technologies

Successfully implementing SDM relies heavily on several key electronic systems that work harmoniously to ensure optimal performance. These include digital control systems, sensor networks, and communication infrastructures, all integral in enabling SDM.

Central to SDM is the use of digital control systems. These systems utilise PLCs to manage and automate production processes. PLCs are responsible for controlling everything from machinery and sensors to conveyors and robotics. By using programmable interfaces, engineers can reconfigure and update control processes quickly and efficiently, allowing for greater flexibility in production (Figure 2).

Figure 2: Key electronic systems, from PLCs to IoT networks, form the foundation of software-defined manufacturing, enabling seamless integration and real-time process control (Source: Paul Hart/imageBROKER/stock.adobe.com)

Another crucial component of SDM is the sensor network. Sensors monitor various aspects of the production environment, such as temperature, pressure, humidity, and machine performance. They provide real-time data that is crucial for ensuring that processes run smoothly and efficiently. The data sensors collect is transmitted to a central control system, where it can be analysed to detect issues, identify inefficiencies, and guide adjustments to the production process.

In addition to sensors, communication infrastructures are essential to SDM. In an SDM environment, devices and systems must communicate seamlessly. This communication is made possible through industrial communication protocols such as Modbus, OPC UA, and Ethernet/IP. These protocols ensure that all devices, including PLCs, sensors, and industrial computers, can exchange data in a standardised and reliable manner, which is critical for the synchronisation and optimisation of the production process.

Finally, industrial computing platforms and Edge devices are vital in enabling SDM. These devices process data locally, at the edge of the network, minimising latency and enabling real-time decision-making. Industrial PCs, for example, are used to manage complex production processes and perform high-level analytics. They also interface with other devices, such as PLCs and sensors, and manage data flow across the system.

Key products powering the future of manufacturing

Here, we explore a few key products that provide the necessary hardware infrastructure to support SDM. These products offer advanced computing capabilities, control systems, and data analytics features that enhance flexibility, productivity, and efficiency.

One such product is the Arduino D1608x Pro Opta Digital Expansions PLC (Figure 3), which is designed to bring programmability and flexibility to SDM environments. The Arduino D1608x is equipped with the Arduino integrated development environment (IDE), a familiar and user-friendly programming environment that makes it easy for engineers to integrate control systems into production processes. The D1608x's modular design allows for quick scalability, enabling manufacturers to expand their SDM capabilities as needed. The PLC’s ability to integrate with other systems makes it a vital component in any SDM-driven production line.

Figure 3: Arduino D1608x Pro Opta Digital Expansions enhances Arduino Opta's real-time control, monitoring, and predictive maintenance applications (Source: Arduino) 

Another product is the Schneider Electric Harmony P6 industrial PC, a high-performance industrial computer built to handle complex, data-intensive production processes in challenging environments. The Harmony P6 provides real-time analytics and data processing capabilities, enabling manufacturers to monitor, control, and optimise production processes more effectively. Its rugged design ensures reliability even in harsh industrial conditions, making it a perfect fit for SDM applications.

The NexCOBOT Coeus-3801T Edge AI computer represents the next generation of computing in SDM. This computer is equipped with powerful Edge AI capabilities, allowing it to process and analyse data locally at the edge of the network. This reduces latency and ensures that decisions can be made in real time, a crucial feature for industries that require continuous process optimisation. The Coeus-3801T can run complex AI models for predictive maintenance, quality control, and process optimisation, making it an invaluable tool for manufacturers seeking to improve efficiency and reduce downtime.

Products like these play a vital role in enabling the SDM revolution. These offerings help manufacturers implement SDM effectively by providing the necessary hardware and software integration, improving flexibility, real-time process optimisation, and predictive maintenance capabilities.

Looking ahead: the future of manufacturing with SDM

SDM is transforming the landscape of modern production, and manufacturers worldwide are increasingly adopting modular, software‑centric architectures to streamline reconfiguration and accelerate time‑to‑market. Today, widespread deployment of virtualised control systems and Cloud‑connected sensor networks is delivering continuous performance insights.

Moving forward, this will continue to expand, and electronics engineers will find new opportunities for innovation, leveraging interoperable soft‑PLC frameworks, secure Edge computing modules, and further integrating AI‑enabled diagnostics tools. These technologies will underpin the next wave of production innovations—enabling plug‑and‑produce retooling, autonomous quality control, and fully integrated digital twins across the supply chain—helping to redefine the speed at which manufacturing environments can adapt to new demands.

As SDM continues to evolve, its potential to revolutionise manufacturing processes becomes even clearer. The integration of advanced electronic systems and cutting-edge technologies will continue to shape the future of manufacturing, making it more efficient, adaptable, and resilient than ever before.