Process Automation Market Forecasts to 2032 – Global Analysis By Offering (Hardware, Software/Systems, and Services), Communication Protocol (Wired Protocols, and Wireless Protocols), Deployment Type, End User, and By Geography
Description
According to Stratistics MRC, the Global Discrete Automation Market is accounted for $187.0 billion in 2025 and is expected to reach $298.4 billion by 2032, growing at a CAGR of 6.9% during the forecast period. Discrete automation is about using robots, controllers, sensors, and machine vision to automate the assembly and manufacturing of individual items like electronics, car parts, and consumer products. Systems enable high precision, repeatability, and flexible production lines for varied product mixes. Adoption is driven by labor dynamics, customization trends, and the need for quality consistency. Vendors emphasize flexible robots, quick-change tooling, and simulation tools to shorten changeover times and enable small-batch, high-variety manufacturing.
Market Dynamics:
Driver:
Increasing labor costs and shortage of skilled workers
Rising labor expenses and a persistent global shortage of skilled manufacturing workers are primary catalysts for discrete automation adoption. More and more businesses are using automation to keep their operations running smoothly and their production levels steady. By deploying robotics and automated systems, businesses can mitigate dependency on manual labor, reduce long-term operational expenditures, and enhance productivity. This strategic shift is critical to sustaining competitiveness, particularly in high-cost regions, thereby directly fueling market growth as automation becomes an economic necessity rather than a luxury for modern manufacturing.
Restraint:
High initial investment and implementation costs
The high initial costs of hardware, software, and systems integration make it hard for small and medium-sized businesses (SMEs) to adopt new technology. This high initial investment includes not only the purchase of robots and controllers but also the costs associated with system design, installation, and employee training. Consequently, the lengthy return on investment period can deter businesses from committing to large-scale automation projects, potentially slowing market penetration in cost-sensitive industrial segments and limiting overall market expansion in the near term.
Opportunity:
Development of collaborative robotics and flexible automation solutions
The emergence of collaborative robots (cobots) and adaptable automation systems opens vast new application areas, particularly for SMEs. Unlike traditional industrial robots, cobots can work safely alongside human workers and are easier to program and redeploy for various tasks. This flexibility allows manufacturers to automate specific processes without completely redesigning production lines. Furthermore, this trend enables high-mix, low-volume production, meeting the demand for customization and creating a significant growth avenue for automation providers targeting previously untapped market segments.
Threat:
Economic volatility affecting capital expenditure in manufacturing sectors
Discrete automation is highly susceptible to economic downturns and fluctuations in industrial output. During periods of economic uncertainty or recession, manufacturers often delay or cancel capital-intensive projects like automation upgrades to preserve cash flow. This cycle of ups and downs is a constant risk to market stability because when companies spend less money, it directly affects new system orders and can cause projects to be delayed. Therefore, the overall health and confidence of the global manufacturing industry closely influences the market's growth.
Covid-19 Impact:
The pandemic initially disrupted the discrete automation market through severe supply chain interruptions and manufacturing shutdowns, stalling project deployments. However, it ultimately acted as a catalyst by exposing the vulnerabilities of reliant human labor. Post-lockdown, the urgent need for operational resilience and social distancing protocols accelerated the adoption of automation. These developments led to a surge in demand for robotics and automated systems as companies sought to de-risk their operations, ensuring business continuity against future disruptions and driving a robust market recovery.
The programmable logic controllers (PLC) segment is expected to be the largest during the forecast period
The programmable logic controllers (PLC) segment is expected to account for the largest market share during the forecast period. The programmable logic controllers (PLC) segment is expected to account for the largest market share during the forecast period. PLCs form the foundational control backbone of most discrete automation systems, governing machinery on factory floors across countless industries. Their enduring dominance is attributed to proven reliability, robustness in harsh industrial environments, and a vast installed base that necessitates continuous replacement and upgrades. The ongoing modernization of aging industrial infrastructure in developed economies and new factory deployments in developing regions ensure consistent demand.
The services segment is expected to have the highest CAGR during the forecast period
Over the forecast period, the services segment is predicted to witness the highest growth rate, driven by the escalating complexity of automation systems. As companies integrate advanced robotics and IoT-enabled solutions, the need for specialized expertise in system integration, consulting, and maintenance intensifies. Moreover, the shift towards predictive maintenance and connected factory ecosystems creates a sustained demand for ongoing support and optimization services. This growth highlights a change in the market where the focus is more on the knowledge and ongoing help needed to keep these advanced systems running smoothly.
Region with largest share:
During the forecast period, the Asia Pacific region is expected to hold the largest market share, anchored by its position as the global manufacturing hub, with China, Japan, and South Korea at the forefront. The region benefits from massive industrial output, strong government initiatives promoting industrial automation, such as ""Made in China 2025,"" and significant investments in upgrading manufacturing capabilities. The large number of car, electronics, and machinery manufacturers in the area creates a strong need for discrete automation solutions, which helps maintain the region's leading position in the global market.
Region with highest CAGR:
Over the forecast period, the Asia Pacific region is anticipated to exhibit the highest CAGR, fueled by the rapid industrialization of emerging economies like India, Vietnam, and Thailand. These countries are actively attracting manufacturing investments, leading to the establishment of new, modern factories equipped with advanced automation. Additionally, rising labor costs in the region are compelling manufacturers to automate in order to sustain competitiveness. This combination of greenfield investments and the pressing need for operational efficiency creates a powerful growth engine, propelling the region's CAGR ahead of other mature markets.
Key players in the market
Some of the key players in Discrete Automation Market include Siemens AG, ABB Ltd., Schneider Electric SE, Rockwell Automation, Inc., Mitsubishi Electric Corporation, Honeywell International Inc., Emerson Electric Co., Omron Corporation, Yokogawa Electric Corporation, FANUC Corporation, Yaskawa Electric Corporation, Bosch Rexroth AG, Delta Electronics, Inc., Beckhoff Automation GmbH & Co. KG, Keyence Corporation, Fuji Electric Co., Ltd., Parker Hannifin Corporation, and General Electric Company.
Key Developments:
In October 2025, Rockwell Automation launched its new ControlLogix® 5590 controller, designed for modern discrete, motion and robotics applications across manufacturing.
In May 2025, Siemens is announcing an expansion of its industrial AI offerings with advanced AI agents designed to work seamlessly across its established Industrial Copilot ecosystem. This new technology represents a fundamental shift from AI assistants that respond to queries towards truly autonomous agents that proactively execute entire processes without human intervention. Siemens' new AI agent architecture features a sophisticated orchestrator. Like a craftsman, it deploys a toolbox of specialized agents to solve complex tasks across the entire industrial value chain.
In March 2025, Siemens introduced advanced AI agents for industrial automation under its Industrial Copilot ecosystem, enabling proactive execution of processes in discrete industries.
Types Covered:
• Programmable Logic Controllers (PLC)
• Manufacturing Execution Systems (MES)
• Product Lifecycle Management (PLM)
• Distributed Control Systems (DCS)
• Other Types
Components Covered:
• Hardware
• Software
• Services
Applications Covered:
• Assembly Line Automation
• Material Handling and Logistics Automation
• Inspection and Quality Control
• Packaging and Palletizing
• Testing and Measurement
End Users Covered:
• Automotive
• Electronics and Semiconductor
• Aerospace and Defense
• Machinery Manufacturing
• Food & Beverage
• Logistics and Warehousing
• Medical Devices and Pharmaceuticals
• Consumer Goods and Packaging
• Textile
• Other End Users
Regions Covered:
• North America
US
Canada
Mexico
• Europe
Germany
UK
Italy
France
Spain
Rest of Europe
• Asia Pacific
Japan
China
India
Australia
New Zealand
South Korea
Rest of Asia Pacific
• South America
Argentina
Brazil
Chile
Rest of South America
• Middle East & Africa
Saudi Arabia
UAE
Qatar
South Africa
Rest of Middle East & Africa
What our report offers:
- Market share assessments for the regional and country-level segments
- Strategic recommendations for the new entrants
- Covers Market data for the years 2024, 2025, 2026, 2028, and 2032
- Market Trends (Drivers, Constraints, Opportunities, Threats, Challenges, Investment Opportunities, and recommendations)
- Strategic recommendations in key business segments based on the market estimations
- Competitive landscaping mapping the key common trends
- Company profiling with detailed strategies, financials, and recent developments
- Supply chain trends mapping the latest technological advancements
Market Dynamics:
Driver:
Increasing labor costs and shortage of skilled workers
Rising labor expenses and a persistent global shortage of skilled manufacturing workers are primary catalysts for discrete automation adoption. More and more businesses are using automation to keep their operations running smoothly and their production levels steady. By deploying robotics and automated systems, businesses can mitigate dependency on manual labor, reduce long-term operational expenditures, and enhance productivity. This strategic shift is critical to sustaining competitiveness, particularly in high-cost regions, thereby directly fueling market growth as automation becomes an economic necessity rather than a luxury for modern manufacturing.
Restraint:
High initial investment and implementation costs
The high initial costs of hardware, software, and systems integration make it hard for small and medium-sized businesses (SMEs) to adopt new technology. This high initial investment includes not only the purchase of robots and controllers but also the costs associated with system design, installation, and employee training. Consequently, the lengthy return on investment period can deter businesses from committing to large-scale automation projects, potentially slowing market penetration in cost-sensitive industrial segments and limiting overall market expansion in the near term.
Opportunity:
Development of collaborative robotics and flexible automation solutions
The emergence of collaborative robots (cobots) and adaptable automation systems opens vast new application areas, particularly for SMEs. Unlike traditional industrial robots, cobots can work safely alongside human workers and are easier to program and redeploy for various tasks. This flexibility allows manufacturers to automate specific processes without completely redesigning production lines. Furthermore, this trend enables high-mix, low-volume production, meeting the demand for customization and creating a significant growth avenue for automation providers targeting previously untapped market segments.
Threat:
Economic volatility affecting capital expenditure in manufacturing sectors
Discrete automation is highly susceptible to economic downturns and fluctuations in industrial output. During periods of economic uncertainty or recession, manufacturers often delay or cancel capital-intensive projects like automation upgrades to preserve cash flow. This cycle of ups and downs is a constant risk to market stability because when companies spend less money, it directly affects new system orders and can cause projects to be delayed. Therefore, the overall health and confidence of the global manufacturing industry closely influences the market's growth.
Covid-19 Impact:
The pandemic initially disrupted the discrete automation market through severe supply chain interruptions and manufacturing shutdowns, stalling project deployments. However, it ultimately acted as a catalyst by exposing the vulnerabilities of reliant human labor. Post-lockdown, the urgent need for operational resilience and social distancing protocols accelerated the adoption of automation. These developments led to a surge in demand for robotics and automated systems as companies sought to de-risk their operations, ensuring business continuity against future disruptions and driving a robust market recovery.
The programmable logic controllers (PLC) segment is expected to be the largest during the forecast period
The programmable logic controllers (PLC) segment is expected to account for the largest market share during the forecast period. The programmable logic controllers (PLC) segment is expected to account for the largest market share during the forecast period. PLCs form the foundational control backbone of most discrete automation systems, governing machinery on factory floors across countless industries. Their enduring dominance is attributed to proven reliability, robustness in harsh industrial environments, and a vast installed base that necessitates continuous replacement and upgrades. The ongoing modernization of aging industrial infrastructure in developed economies and new factory deployments in developing regions ensure consistent demand.
The services segment is expected to have the highest CAGR during the forecast period
Over the forecast period, the services segment is predicted to witness the highest growth rate, driven by the escalating complexity of automation systems. As companies integrate advanced robotics and IoT-enabled solutions, the need for specialized expertise in system integration, consulting, and maintenance intensifies. Moreover, the shift towards predictive maintenance and connected factory ecosystems creates a sustained demand for ongoing support and optimization services. This growth highlights a change in the market where the focus is more on the knowledge and ongoing help needed to keep these advanced systems running smoothly.
Region with largest share:
During the forecast period, the Asia Pacific region is expected to hold the largest market share, anchored by its position as the global manufacturing hub, with China, Japan, and South Korea at the forefront. The region benefits from massive industrial output, strong government initiatives promoting industrial automation, such as ""Made in China 2025,"" and significant investments in upgrading manufacturing capabilities. The large number of car, electronics, and machinery manufacturers in the area creates a strong need for discrete automation solutions, which helps maintain the region's leading position in the global market.
Region with highest CAGR:
Over the forecast period, the Asia Pacific region is anticipated to exhibit the highest CAGR, fueled by the rapid industrialization of emerging economies like India, Vietnam, and Thailand. These countries are actively attracting manufacturing investments, leading to the establishment of new, modern factories equipped with advanced automation. Additionally, rising labor costs in the region are compelling manufacturers to automate in order to sustain competitiveness. This combination of greenfield investments and the pressing need for operational efficiency creates a powerful growth engine, propelling the region's CAGR ahead of other mature markets.
Key players in the market
Some of the key players in Discrete Automation Market include Siemens AG, ABB Ltd., Schneider Electric SE, Rockwell Automation, Inc., Mitsubishi Electric Corporation, Honeywell International Inc., Emerson Electric Co., Omron Corporation, Yokogawa Electric Corporation, FANUC Corporation, Yaskawa Electric Corporation, Bosch Rexroth AG, Delta Electronics, Inc., Beckhoff Automation GmbH & Co. KG, Keyence Corporation, Fuji Electric Co., Ltd., Parker Hannifin Corporation, and General Electric Company.
Key Developments:
In October 2025, Rockwell Automation launched its new ControlLogix® 5590 controller, designed for modern discrete, motion and robotics applications across manufacturing.
In May 2025, Siemens is announcing an expansion of its industrial AI offerings with advanced AI agents designed to work seamlessly across its established Industrial Copilot ecosystem. This new technology represents a fundamental shift from AI assistants that respond to queries towards truly autonomous agents that proactively execute entire processes without human intervention. Siemens' new AI agent architecture features a sophisticated orchestrator. Like a craftsman, it deploys a toolbox of specialized agents to solve complex tasks across the entire industrial value chain.
In March 2025, Siemens introduced advanced AI agents for industrial automation under its Industrial Copilot ecosystem, enabling proactive execution of processes in discrete industries.
Types Covered:
• Programmable Logic Controllers (PLC)
• Manufacturing Execution Systems (MES)
• Product Lifecycle Management (PLM)
• Distributed Control Systems (DCS)
• Other Types
Components Covered:
• Hardware
• Software
• Services
Applications Covered:
• Assembly Line Automation
• Material Handling and Logistics Automation
• Inspection and Quality Control
• Packaging and Palletizing
• Testing and Measurement
End Users Covered:
• Automotive
• Electronics and Semiconductor
• Aerospace and Defense
• Machinery Manufacturing
• Food & Beverage
• Logistics and Warehousing
• Medical Devices and Pharmaceuticals
• Consumer Goods and Packaging
• Textile
• Other End Users
Regions Covered:
• North America
US
Canada
Mexico
• Europe
Germany
UK
Italy
France
Spain
Rest of Europe
• Asia Pacific
Japan
China
India
Australia
New Zealand
South Korea
Rest of Asia Pacific
• South America
Argentina
Brazil
Chile
Rest of South America
• Middle East & Africa
Saudi Arabia
UAE
Qatar
South Africa
Rest of Middle East & Africa
What our report offers:
- Market share assessments for the regional and country-level segments
- Strategic recommendations for the new entrants
- Covers Market data for the years 2024, 2025, 2026, 2028, and 2032
- Market Trends (Drivers, Constraints, Opportunities, Threats, Challenges, Investment Opportunities, and recommendations)
- Strategic recommendations in key business segments based on the market estimations
- Competitive landscaping mapping the key common trends
- Company profiling with detailed strategies, financials, and recent developments
- Supply chain trends mapping the latest technological advancements
Table of Contents
200 Pages
- 1 Executive Summary
- 2 Preface
- 2.1 Abstract
- 2.2 Stake Holders
- 2.3 Research Scope
- 2.4 Research Methodology
- 2.4.1 Data Mining
- 2.4.2 Data Analysis
- 2.4.3 Data Validation
- 2.4.4 Research Approach
- 2.5 Research Sources
- 2.5.1 Primary Research Sources
- 2.5.2 Secondary Research Sources
- 2.5.3 Assumptions
- 3 Market Trend Analysis
- 3.1 Introduction
- 3.2 Drivers
- 3.3 Restraints
- 3.4 Opportunities
- 3.5 Threats
- 3.6 End User Analysis
- 3.7 Emerging Markets
- 3.8 Impact of Covid-19
- 4 Porters Five Force Analysis
- 4.1 Bargaining power of suppliers
- 4.2 Bargaining power of buyers
- 4.3 Threat of substitutes
- 4.4 Threat of new entrants
- 4.5 Competitive rivalry
- 5 Global Process Automation Market, By Offering
- 5.1 Introduction
- 5.2 Hardware
- 5.2.1 Controllers
- 5.2.2 Field Instruments
- 5.2.3 Industrial PCs and HMIs
- 5.2.4 Motors and Drives
- 5.2.5 Process Safety Systems (SIS)
- 5.3 Software/Systems
- 5.3.1 Supervisory Control and Data Acquisition (SCADA)
- 5.3.2 Distributed Control Systems (DCS)
- 5.3.3 Manufacturing Execution Systems (MES)
- 5.3.4 Advanced Process Control (APC)
- 5.3.5 Other Software
- 5.4 Services
- 5.4.1 Consulting & Design
- 5.4.2 Integration & Implementation
- 5.4.3 Maintenance & Support
- 6 Global Process Automation Market, By Communication Protocol
- 6.1 Introduction
- 6.2 Wired Protocols
- 6.3 Wireless Protocols
- 7 Global Process Automation Market, By Deployment Type
- 7.1 Introduction
- 7.2 On-Premise
- 7.3 Cloud-Based
- 8 Global Process Automation Market, By End User
- 8.1 Introduction
- 8.2 Oil & Gas
- 8.3 Chemical & Petrochemical
- 8.4 Energy & Power
- 8.5 Water & Wastewater Treatment
- 8.6 Food & Beverages
- 8.7 Pharmaceuticals & Life Sciences
- 8.8 Pulp & Paper
- 8.9 Metals & Mining
- 8.10 Other End Users
- 9 Global Process Automation Market, By Geography
- 9.1 Introduction
- 9.2 North America
- 9.2.1 US
- 9.2.2 Canada
- 9.2.3 Mexico
- 9.3 Europe
- 9.3.1 Germany
- 9.3.2 UK
- 9.3.3 Italy
- 9.3.4 France
- 9.3.5 Spain
- 9.3.6 Rest of Europe
- 9.4 Asia Pacific
- 9.4.1 Japan
- 9.4.2 China
- 9.4.3 India
- 9.4.4 Australia
- 9.4.5 New Zealand
- 9.4.6 South Korea
- 9.4.7 Rest of Asia Pacific
- 9.5 South America
- 9.5.1 Argentina
- 9.5.2 Brazil
- 9.5.3 Chile
- 9.5.4 Rest of South America
- 9.6 Middle East & Africa
- 9.6.1 Saudi Arabia
- 9.6.2 UAE
- 9.6.3 Qatar
- 9.6.4 South Africa
- 9.6.5 Rest of Middle East & Africa
- 10 Key Developments
- 10.1 Agreements, Partnerships, Collaborations and Joint Ventures
- 10.2 Acquisitions & Mergers
- 10.3 New Product Launch
- 10.4 Expansions
- 10.5 Other Key Strategies
- 11 Company Profiling
- 11.1 Siemens AG
- 11.2 ABB Ltd.
- 11.3 Schneider Electric SE
- 11.4 Honeywell International Inc.
- 11.5 Emerson Electric Co.
- 11.6 Rockwell Automation, Inc.
- 11.7 Mitsubishi Electric Corporation
- 11.8 Yokogawa Electric Corporation
- 11.9 Omron Corporation
- 11.10 General Electric Company
- 11.11 Bosch Rexroth AG
- 11.12 Fuji Electric Co., Ltd.
- 11.13 Delta Electronics, Inc.
- 11.14 Phoenix Contact GmbH & Co. KG
- 11.15 Beckhoff Automation GmbH & Co. KG
- 11.16 Aspen Technology, Inc.
- 11.17 AVEVA Group plc
- 11.18 Endress+Hauser AG
- List of Tables
- 1 Global Process Automation Market Outlook, By Region (2024–2032) ($MN)
- 2 Global Process Automation Market Outlook, By Offering (2024–2032) ($MN)
- 3 Global Process Automation Market Outlook, By Hardware (2024–2032) ($MN)
- 4 Global Process Automation Market Outlook, By Controllers (2024–2032) ($MN)
- 5 Global Process Automation Market Outlook, By Field Instruments (2024–2032) ($MN)
- 6 Global Process Automation Market Outlook, By Industrial PCs and HMIs (2024–2032) ($MN)
- 7 Global Process Automation Market Outlook, By Motors and Drives (2024–2032) ($MN)
- 8 Global Process Automation Market Outlook, By Process Safety Systems (SIS) (2024–2032) ($MN)
- 9 Global Process Automation Market Outlook, By Software/Systems (2024–2032) ($MN)
- 10 Global Process Automation Market Outlook, By Supervisory Control and Data Acquisition (SCADA) (2024–2032) ($MN)
- 11 Global Process Automation Market Outlook, By Distributed Control Systems (DCS) (2024–2032) ($MN)
- 12 Global Process Automation Market Outlook, By Manufacturing Execution Systems (MES) (2024–2032) ($MN)
- 13 Global Process Automation Market Outlook, By Advanced Process Control (APC) (2024–2032) ($MN)
- 14 Global Process Automation Market Outlook, By Other Software (2024–2032) ($MN)
- 15 Global Process Automation Market Outlook, By Services (2024–2032) ($MN)
- 16 Global Process Automation Market Outlook, By Consulting & Design (2024–2032) ($MN)
- 17 Global Process Automation Market Outlook, By Integration & Implementation (2024–2032) ($MN)
- 18 Global Process Automation Market Outlook, By Maintenance & Support (2024–2032) ($MN)
- 19 Global Process Automation Market Outlook, By Communication Protocol (2024–2032) ($MN)
- 20 Global Process Automation Market Outlook, By Wired Protocols (2024–2032) ($MN)
- 21 Global Process Automation Market Outlook, By Wireless Protocols (2024–2032) ($MN)
- 22 Global Process Automation Market Outlook, By Deployment Type (2024–2032) ($MN)
- 23 Global Process Automation Market Outlook, By On-Premise (2024–2032) ($MN)
- 24 Global Process Automation Market Outlook, By Cloud-Based (2024–2032) ($MN)
- 25 Global Process Automation Market Outlook, By End User (2024–2032) ($MN)
- 26 Global Process Automation Market Outlook, By Oil & Gas (2024–2032) ($MN)
- 27 Global Process Automation Market Outlook, By Chemical & Petrochemical (2024–2032) ($MN)
- 28 Global Process Automation Market Outlook, By Energy & Power (2024–2032) ($MN)
- 29 Global Process Automation Market Outlook, By Water & Wastewater Treatment (2024–2032) ($MN)
- 30 Global Process Automation Market Outlook, By Food & Beverages (2024–2032) ($MN)
- 31 Global Process Automation Market Outlook, By Pharmaceuticals & Life Sciences (2024–2032) ($MN)
- 32 Global Process Automation Market Outlook, By Pulp & Paper (2024–2032) ($MN)
- 33 Global Process Automation Market Outlook, By Metals & Mining (2024–2032) ($MN)
- 34 Global Process Automation Market Outlook, By Other End Users (2024–2032) ($MN)
- Note: Tables for North America, Europe, APAC, South America, and Middle East & Africa Regions are also represented in the same manner as above.
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