The Manufacturing Supply Chain Journey through AI and Automation

Manufacturing Supply Chains Explained 

The manufacturing supply chain comprises all the processes a business uses to turn raw materials and components into final products that are ready to be sold to customers, whether these are consumers or other businesses. Supply chain processes include procurement from source to pay, together with inbound logistics, production, quality control, outbound logistics and post-sales service.  

A supply chain is thus a complex sequence of operations. If any link in the chain becomes broken, disjointed, or inefficient, the business becomes less likely to keep up with customer demand. In today’s highly competitive market, where there is an expectation of rapid delivery, every link in the supply chain is critically important to ensure that products are manufactured efficiently, and waste is minimized. 

Supply chain management (SCM) is the broad range of activities required to plan, control and execute a manufactured product’s supply chain from materials to production to distribution in the most economical way possible. SCM encompasses the integrated planning and execution of processes required to optimize the flow of materials, information, and capital in functions that broadly include demand planning, sourcing, production, inventory management and logistics. 

The rise of supply chain management as a distinct function reflected a more integrated approach to operations management. This recognizes the interconnected nature of procurement, production, logistics, and distribution. Before ‘Supply Chain Manager’ became a common job title in the 1990s, professionals responsible for a part of the activity had titles such as Logistics Manager, Materials Manager, Operations Manager etc. 

The emergence of supply chain management was driven by the rise of globalization and advances in information technology (e.g., ERP systems), requiring a more integrated approach to supply flows. 

Components of a Modern Supply Chain 

There are of course differences between sectors, but taking the automotive industry as an example, a modern supply chain typically consists of the following seven elements.  

Direct material management oversees the sourcing, procurement, storage, and flow of raw materials, components, and subassemblies. This ensures just-in-time (JIT) or just-in-sequence (JIS) delivery to reduce inventory costs. Direct material management involves demand forecasting, inventory control, and warehouse operations. 

Product lifecycle management (PLM) manages a vehicle’s lifecycle from concept to end-of-life recycling. It covers design, prototyping, engineering changes, and regulatory compliance. PLM integrates digital twins, CAD systems, and collaboration between R&D and manufacturing. 

Supplier management involves selecting, onboarding, and maintaining relationships with tier 1 suppliers and those further up the supply chain (tiers 2 and upward). Effective supplier management ensures quality control, risk mitigation, and compliance with sustainability and ethical sourcing standards. Tools used here include supplier scorecards, audits, and performance tracking. Above all, today’s supplier management relies on supplier intelligence and analytics. 

Supply chain logistics manages the inbound transportation of materials and outbound distribution of finished vehicles. This includes warehousing, customs clearance, multimodal transport (road, rail, air, sea), and last-mile delivery. Tools and methods used include real-time tracking, RFID, and AI-driven route optimization. 

Manufacturing & production planning (often linked to material management) coordinates assembly line scheduling, workforce allocation, and resource planning. In today’s advanced manufacturing, it integrates robotics, IoT, and automation in smart factories. Lean manufacturing principles are applied to reduce waste and enhance efficiency. 

Risk & sustainability management monitors geopolitical, environmental, and supplier-related risks. It ensures compliance with emission standards, ethical labor practices, and circular economy initiatives. Today there is a focus on EV battery supply chains, rare earth material sourcing, and recycling programs. 

Demand & sales forecasting is a related discipline which uses market data, historical trends, and AI-driven analytics to predict demand to help optimize production volumes and distribution networks. It also aligns with dealership and aftermarket service strategies. 

Key Challenges in Manufacturing Supply Chains and Solutions 

The world is currently going through an era of unprecedented challenges in supply chain management.  

First, there are several issues around supply chain resilience and risk management due to geopolitical instability, with conflicts such as the Russia-Ukraine war and tensions in the Middle East disrupting supply routes and trade relations. Extreme weather events (hurricanes, floods, wildfires) increasingly impact logistics and production. And cybersecurity threats against logistics companies and suppliers pose risks to data integrity and operations. 

Second, trade tensions are destabilizing globalized supply flows and creating uncertainties. The tariffs announced by the United States on April 2, 2025 have not only forced supply chain managers to reconsider where they source materials but even raise questions about where to locate production facilities. Sanctions, export controls and restrictions on key materials (e.g., semiconductors) further disrupt supply flows. 

Third, sustainability and ESG concerns have emerged in recent years. Manufacturing supply chain managers are under pressure to reduce their firms’ carbon footprint with green logistics (e.g., electric fleets, sustainable packaging). Legislation such as the German Supply Chain Due Diligence Act mean there is increased scrutiny of labor practices, especially in regions with forced labor concerns (e.g., Xinjiang cotton, cobalt mining). There is also pressure to improve recycling, reduce waste, and design products for longevity. 

Fourth, competition is driving digitalization and the introduction of advanced technologies into supply chain management. But many companies struggle with fragmented IT systems, which inhibits their agility (for example by making real-time tracking impossible) and other data integration challenges. While they hold great promise, the implementation of AI-driven demand forecasting and robotic process automation (RPA) is slow. Ensuring transparency in sourcing (e.g., lithium-ion batteries for EVs) is likewise complex despite the availability of blockchain technology. 

Fifth, the skills gap is a challenge in SCM. Companies face difficulties in recruiting skilled labor in areas such as logistics and IT, which slows down innovation. 

Sixth, although inflation has eased recently, cost pressures remain in some areas and there have been shortages of some components such as semiconductors. Rising energy costs have impacted European manufacturers in particular. Port congestion and container shortages have driven up transport expenses. There is current uncertainty about the direction of interest rates, and higher borrowing costs make supply chain investments (e.g., automation, infrastructure) more expensive. 

Strategies for Optimization the Manufacturing Supply Chain

For each of the challenges listed above, manufacturers are adopting strategies to overcome or mitigate them. Those that succeed in leveraging technology, supplier collaboration, and risk management frameworks can significantly improve resilience, efficiency, and sustainability in their supply chains. 

To reduce risk and increase resilience, manufacturers are deploying risk management software and diversifying their suppliers. AI-powered risk management platforms can predict disruptions (e.g., geopolitical risks and extreme weather). A multi-supplier strategy and reshoring/nearshoring key components can reduce reliance on high-risk regions. It also makes sense to develop contingency plans with alternative logistics routes and emergency inventory buffers. 

To mitigate shocks from tariffs and trade barriers, manufacturers are restructuring supply networks and improving their compliance tracking. For example, some are establishing regional production hubs to bypass tariff-heavy regions. By investing in customs and trade compliance software they can automate tariff calculations and ensure they adhere to local regulations. Longer term, they lobby their governments to reduce duty costs on imports/exports. 

Manufacturers are acting on sustainability for several reasons (government pressure, consumer pressure, regulations, cost considerations). Measures include supply chain traceability tools, now using blockchain, to verify ethical sourcing of materials such as lithium, cobalt, and rare earth metals. Greater use of renewable energy and circular economy models, promoting remanufacturing, recycling, and extended product lifecycles, are reducing environmental damage. 

Over time, it will become easier to deploy AI-driven SCM software and IoT for real-time tracking. Integrated SCM and source-to-pay software will provide end-to-end visibility, and if it is further integrated with AI-driven demand forecasting manufacturers will be better able to predict fluctuations and adjust inventory dynamically. IoT sensors & RFID tracking enable real-time monitoring of shipments, reducing theft and delays. 

Technology is also key to overcoming the skills shortage, but this must go hand-in-hand with workforce upskilling. Manufacturers must automate repetitive tasks using technologies such as robotic process automation (RPA) and collaborative robots (cobots) in factories. They can implement digital twins to simulate factory workflows and optimize workforce allocation. Meanwhile, they must invest in reskilling initiatives, training employees in AI-driven supply chain analytics and digital tools. This will have the further benefit of making manufacturing supply chain management a more attractive career choice. 

Manufacturers cannot control inflation, but they can reduce costs by optimizing their procurement strategies. Source-to-pay platforms such as JAGGAER, and in particular sourcing software such as JAGGAER Advanced Sourcing Optimizer, are especially effective for complex categories such as logistics. Increasingly they will use AI-based procurement tools to negotiate the best contract terms at speed. 

The Future of Supply Chain Management 

It is clear that technology will be central to the future development of supply chain management. Data quality is key to success, as is the ability to integrate diverse IT platforms: ERP, MES, EAM, S2C and more. Mass customization—offering personalized products at scale—is a trend that challenges traditional supply chain models by increasing complexity in procurement, production, inventory, and logistics. We can expect to see greater reliance on smart factories and a shift towards on-demand, pull-based supply chains (manufacturing in response to real-time customer orders).

BMW has moved in this direction, for example, with a ‘Build-to-Order’ model that reduces finished vehicle inventory while enabling high levels of customization. Companies must become increasingly agile to manage this transition. Logistics and last mile functions are adapting to the new reality, for example Nike’s NIKEiD customization platform uses regional micro-factories to speed up deliveries. Its competitor Adidas uses Speedfactories with robotic automation to produce customized shoes close to customers. 

We may see drones and autonomous vehicles deployed for last-mile delivery. 

This will further advanced technologies such as additive manufacturing, predictive analytics, the Internet of Things, blockchain and cloud-based SCM systems. Mercedes Benz is piloting blockchain to track sustainability in customized vehicle components. 

Conclusion 

The concept of supply chain management is relatively new, but the speed of change has been breathtaking and continues to accelerate, despite the obstacles and challenges.  

In many industries, such as automotive, fashion and electronics, mass customization is disrupting traditional supply chains by increasing complexity, requiring greater agility, and driving digital transformation and automation across procurement, production, and logistics. Companies investing in AI, automation, blockchain, and additive manufacturing will be best positioned to scale customization profitably. 

Food manufacturing supply chains are also evolving rapidly, driven by automation, sustainability, and changing consumer preferences. Currently, AI-powered food processing, robotic process automation, and IoT-enabled smart factories are improving efficiency and reducing waste. Food traceability using blockchain is increasing transparency in sourcing and safety.  

Looking ahead, personalized nutrition (AI-driven meal customization based on genetics and health data) and 3D-printed foods could reshape production. Additionally, climate-smart agriculture and vertical farming will further integrate into farm-to-fork supply chains to enhance resilience and reduce carbon footprints. 

Perhaps it won’t be long before AI-powered logistics networks will integrate robotic warehouses and last-mile drone deliveries for perishable goods, including made-to-order meals.