Views & Visions

Contrary to fears of job displacement by Artificial Intelligence (AI) and automation, advanced manufacturing skillsets are in high demand and growing. Nationally, Deloitte reports more than 380,000 open positions; anecdotally, in recent years at the Marshall Advanced Manufacturing Center (MAMC), we have experienced the same level of demand from industry in West Virginia. Now, thanks to a study by Marshall University’s Center for Business & Economics Research, we have that demand documented here also. Specifically, 83 Mountain State manufacturers detailed 2,768 positions needed now, plus an additional 4,226 over the next three years.

These positions increasingly require employees to be adept with more advanced equipment and software. Additionally, in the real world on the plant floor, most manufacturers have a wide array of equipment brands installed over many decades that all must work together. This requires nimble employees who can troubleshoot and commit to lifelong learning.

Add AI into this mix and you might wonder if it is too much to handle. After all, AI impacts everything, from software to production equipment processes. As it is integrated more deeply into the industrial sector, manufacturers and their employees must understand the technology to take full advantage of its benefits. As that is occurring, AI is also increasingly seen as a tool to augment human capabilities.

AI Applications in Manufacturing

AI has been quietly revolutionizing manufacturing for years, long before its recent rise to mainstream attention that is penetrating all facets of society. Early applications saw AI-like software begin improving predictive maintenance and quality control inspection equipment in factories. More recently, AI components have been integrated into common Computer-Aided Design (CAD) and Computer-Aided Machining (CAM) software, increasing efficiencies of engineers and machinists. Moreover, AI accelerates innovation cycles. Generative design tools use AI to explore thousands of design permutations based on performance criteria, material constraints, and manufacturing methods. This can help a trained employee design lighter, stronger, and more cost-effective components.

AI’s most immediate impact on manufacturing is its ability to optimize production processes. Machine learning algorithms can analyze vast amounts of sensor data to detect inefficiencies, predict equipment failures, and recommend process improvements. This predictive capability reduces downtime, minimizes waste, and enhances overall productivity. In sectors such as aerospace, automotive, and precision machining – key industries in West Virginia – AI-driven automation is enabling manufacturers to meet tighter tolerances and faster turnaround times.

Most people think of robotics as a high-tech field and, with AI powered software helping programmers write code better and faster, it’s having a big impact as well. Newer tech like collaborative robots (cobots), guided by AI, are working alongside skilled technicians to handle repetitive or hazardous tasks, freeing workers to focus on higher-value activities such as programming, maintenance, and innovation.  

Quality control and precision measurement are also being enhanced by AI. Computer vision systems powered by AI are a primary driver for improving quality assurance. These systems can inspect products at high speeds with greater accuracy than human inspectors, identifying defects that might otherwise go unnoticed. This not only improves product quality but also reduces the cost of recalls and rework and allows for greater product miniaturization.

MAMC wants to ensure the next generation of industrial maintenance systems technicians understand how all this technology impacts equipment systems on automated production lines. Our SMART (Systems Maintenance, Automation and Robotics Technology) career skills program immerses students in these technological advances so they have the skills and knowledge that manufacturers need to fully leverage the benefits of robotics, AI, and machining learning. We created this program in partnership with Mountwest Community & Technical College and two dozen state and regional manufacturers that need workers with these critical skills.

Challenges and Strategic Opportunities

Despite its promise, AI adoption in manufacturing is not without hurdles. Data integration, cybersecurity, and the need for skilled personnel are among the top concerns. Many manufacturers struggle with legacy systems that are not easily compatible with AI technologies or simply lack fast enough internet service to run AI. Addressing these challenges requires coordinated efforts in infrastructure, education (at all levels), and workforce training.

AI is rapidly reshaping the manufacturing landscape, ushering in more efficiency, precision, and innovation. From predictive maintenance to quality control, AI technologies are driving significant changes across production lines, supply chains, and workforce dynamics. For regions like West Virginia, where advanced manufacturing is a cornerstone for improving economic development, the integration of AI presents both opportunities and challenges. We must get our workforce ready so that individuals can fill these advanced technical positions. Filling the state’s 7,000 advanced manufacturing job openings would not only strengthen the sector but could also transform our economy – creating thousands of families with above-average incomes and revitalizing communities across the Mountain State.

Derek Scarbro joined the Marshall Advanced Manufacturing Center (MAMC) in 2017 and became Director in 2022. For 35 years, MAMC has been focused on applied workforce and economic development in manufacturing. It serves more than 300 companies and trains more than 1,000 people annually.

Prior to MAMC, he served in various state government agencies, like the Governor’s Office, Treasurer’s Office, Development Office, and led statewide non-profit organizations. While in the Governor’s Office he served as the Director of Intergovernmental Affairs and was the gubernatorial appointee on the Interagency Workforce Development Taskforce.

Derek lives in Huntington with his wife, Sara Payne, and daughter, Willa. He serves on boards for the Regional Contracting Assistance Center, Marshall’s Council for Research and Commercialization, Tech Connect, and the United Way.