Today’s factories often face a critical issue: product design, automation, and production systems operate in silos. This fragmentation leads to longer commissioning times, higher error risks, and limited flexibility. OMRON and Dassault Systèmes are breaking down these barriers by creating a seamless link between 3D design and simulation in the virtual world, and robots, sensors and production lines in the physical world.

The collaboration combines Dassault Systèmes’ 3D UNIV+RSES with OMRON’s Sysmac industrial automation platform, enabling manufacturers to design, simulate, validate and deploy production systems within a continuous virtual environment. At the core of the partnership is the Virtual Twin of Production Systems, which allows companies to test a new production line, validate robot behaviour, or optimise logistics flows – prior to building anything physically.

Thanks to this IT/OT convergence, manufacturers benefit from a digital continuum before deployment and during operations. Production lines are designed, simulated, and validated in a virtual environment augmented by Virtual Companions. Performance, safety, maintenance and other scenarios are tested to correct errors before real-world deployment. Once the physical line is installed, real-time data from sensors, controllers, and robots is fed back into the virtual twin. This enables comparison between real and simulated behaviour, fine-tuning, and predictive maintenance to reduce costs and risks.

“Manufacturing is entering a new era. With OMRON, we are building living production systems, AI-driven, self-improving, and software-defined, where the virtual and physical worlds are fused into one continuous loop of learning. Our industry world models transform complexity into intelligence, making factories not just automated, but autonomous. This is how we reinvent industrial systems, from reactive to predictive, from rigid to adaptive and define the next frontier of manufacturing,” said Pascal Daloz, CEO, Dassault Systèmes.

“Our partnership with Dassault Systèmes strengthens our ability to integrate the OT and IT worlds and provide customers with a holistic solution from simulated to fully implemented, intelligent production,” said Motohiro Yamanishi, Company President of the Industrial Automation Company (IAB), OMRON Corporation.

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For more than 200 years, manufacturing has been built upon the single principle of control. It delivered scale, efficiency, and global supply chains, but it was designed for a predictable world.

Today, as Europe’s manufacturers face energy uncertainty, labour shortages, and mounting sustainability pressures, a new industrial model is emerging: one that replaces rigid control with flexible coexistence – providing a framework in which people, machines, and the planet work together, through autonomy and collaboration, towards a shared purpose.

The limits of control

Since the Industrial Revolution, manufacturers have been working on gaining ever greater control – over their machines, processes, resources, and manpower.

The introduction of the steam engine in the late 1700s allowed factories to run machinery at a predictable, steady speed for the first time, for example, while the moving assembly line established control over the flow and pace of production. Control has powered mass production and enabled global supply chains, but it is reaching its limits.

To control a parameter, we first need to predict it. Yet, as Ikuo Tateishi, president of the Human Renaissance Institute and grandson of OMRON’s founder, Kazuma Tateishi, highlighted at Osaka Expo 2025, today’s world is anything but predictable.

Towards coexistence

As a society, we face climate volatility, energy insecurity, demographic contraction, and geopolitical fragmentation. In Europe, energy costs are high, labour is scarce, and global is competition is intense.

In this landscape, success will depend not on harnessing control to accelerate scale or speed, but on our ability to combine technology, human values, and collaboration into a more resilient model of progress. The key is replacing the pursuit of control with adaptive, co-created networks that connect people, machines and the planet.

More than 50 years ago, Kazuma Tateishi predicted that society would evolve from a focus on efficiency and optimisation, to autonomous systems that can self-organise and learn. He foresaw a so-called ‘natural society’ where humans, technology and nature coexist in balance.

We now see his theory unfolding in factories around the world. Machines that sense, decide and adapt in real time, production systems that respond dynamically to variation, and factories that share operational data to improve energy and material efficiency have all become realities.

This machine autonomy is not about removing people, but amplifying their intent. Moving from control to coexistence means enabling technology that listens, collaborates, and creates space for human creativity and purpose.

Six shifts toward a coexistence economy

Moving from control to coexistence requires a fundamental rethink of how manufacturing is designed and run. The path ahead is not a single innovation, but a connected transformation across technology, culture and collaboration.

Europe’s manufacturing future depends on six key shifts. The first is from isolated efficiency to systemic resilience – moving beyond pure productivity to systems that can adapt, predict disruption, and remain stable in volatile conditions. Manufacturers also need to move from competition to co-creation, collaborating across industries, governments and research to solve shared challenges and accelerate innovation for the greater good.

In addition, we must move from linear production to circular design, replacing take-make-dispose models with systems that reduce waste, recover materials and regenerate energy. At the same time, we must also shift from central control to distributed intelligence, enabling autonomous, connected systems that learn locally but improve globally, thereby increasing agility and resilience across the system.

As automation advances, the focus must expand from efficiency to transparency, building trust through explainable, ethical, and accountable systems that people can understand and oversee. Finally, predictability must give way to adaptability, with flexible organisations and technologies that can respond quickly to change without sacrificing stability.

Together, these six key shifts define a manufacturing model where people, technology, and the environment coexist to create sustainable, resilient value.

A realistic path forward

Every industrial revolution has been an upgrade of our collective operating system, and the upcoming step change is no exception. Yet moving from control to coexistence will not be easy.

While success will rely on industry, technology and society evolving together, the political and economic climate in many regions already favours protectionism over collaboration. Together, we must highlight our shared purpose and build an understanding of the mutual benefits of coexistence.

There are also legitimate concerns around job displacement, data security and ethical AI, all of which must be addressed sympathetically and with transparency. We need to share the message that coexistence is not about replacing people with machines, but reconnecting technology to purpose.

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The TM30S, TM20S and TM6S extend the series’ payload and reach capabilities for applications such as palletising, machine tending and precision handling.

• TM30S: 30 kg payload model designed for heavy-duty collaborative tasks including palletising and machine tending.
• TM20S: 20 kg payload unit offering extended reach for mid-to-high payload operations.
• TM6S: Long-reach 6 kg payload model optimised for precision handling, welding support and mobile robot integration.

Across the S Series, OMRON has introduced upgrades to increase durability and support faster redeployment. All robot arms now feature an IP65 rating for use in washdown or dust-prone environments. Higher-payload units (TM25S, TM30S) incorporate an integrated joint 6 force-torque wrist sensor for improved force-controlled processes. The updated Landmark 2.0 vision-based positioning system is designed to reduce recalibration time when moving robots between stations.

TMflow 2.22 software release

OMRON has also released TMflow 2.22, an update to its no-code programming environment. The new version introduces more granular safety configuration options, expanded remote monitoring and diagnostics and a higher-fidelity simulation engine. Integrated vision tools have been strengthened to support inspection and pick-and-place tasks with greater accuracy.

“By introducing the TM30S, TM20S, and TM6S alongside crucial upgrades like IP65 certification and the integrated joint 6 force torque sensor, we are empowering our customers to automate their most challenging, heavy-duty tasks with greater safety, precision, and flexibility than ever before,” said Qiqi Wang, Global Product Manager at OMRON Robotics and Safety Technologies. “TMflow 2.22 ensures that this immense power remains easy to program and manage, upholding our commitment to harmonious automation.”

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To modernise one of its key packing lines, CP Foods UK partnered with Gripple, the Sheffield-based engineering company known for its innovative approach to automation projects, and OMRON, a global leader in industrial automation. Together, they developed and installed a robotic solution that has improved efficiency and reliability, whilst re-energising the workforce.

Meeting changing retail demands with agility

The challenge was ambitious from the start. As Craig Bagnall, operations manager at Gripple, explained: “CP Foods challenged us to deliver them a product that picked and placed chicken in sealed trays at 120 packs per minute, at an 85% OEE, with a 1% reject.”

For CP Foods UK, automation means building resilience into the business and maintaining flexibility in the face of rapidly changing customer requirements. Adele Davies, Factory general manager at CP Foods, described the situation: “The things that we’re having to think about at the moment is, how do we cope with ever-changing requirements from retailers and customers, and how do we remain flexible as well as having automation? We previously had a line that would require you to put trays on a line as well as people manual packing, so we did a full automation project.”

The existing infrastructure was no longer fit for purpose. Andy White, engineering manager at CP Foods UK, explained that the equipment in the low-care area had reached the end of its life. The line had been “patched together” over time and required constant maintenance. Rather than continue to sustain ageing systems, the company saw an opportunity to embrace new technology. “We wanted a solution that not only improved performance, but also made the job more rewarding for our engineers and for the people working on the line,” White said.

Servo-driven robotics with integrated control

Working closely together, Gripple and OMRON engineers designed a bespoke robotic packaging machine tailored to CP Foods UK’s exact needs. At the time, there was nothing on the market that could deliver the combination of speed, reliability, accuracy, and compact footprint required. The collaboration between the two engineering teams was crucial in identifying the best way forward, resulting in a servo-driven machine that operates more quietly and smoothly while offering clear improvements for the end user.

One of the key breakthroughs was the development of a new gripper system. Dan Matthews, Mechanical Design Engineer at Gripple, noted: “Most important probably is understanding the end customer’s needs. Understanding their production environment, understanding the rest of the line, and making sure that our equipment seamlessly integrates with all that. Because the machine operates at 120 parts a minute, we had to develop something that could stack multiple packs at once. We developed a multi-stack gripper that could do five picks and then place, and we collaborated with the OMRON robotics engineers to develop the software alongside our own.”

Behind the mechanical innovation sits OMRON’s Sysmac automation platform, which provides the backbone of the solution. Sysmac integrates all aspects of the machine into one environment, covering PLC control, vision systems, cameras, sensor data, robotics, safety, and servo drives. By managing everything through a single piece of software, the platform simplifies operation, whilst delivering the performance and flexibility needed for high-speed food production.

Meeting throughput goals and inspiring people

The new system has been a success on several fronts. From an operational perspective, the line now meets the high-speed throughput targets while ensuring consistency and reliability in a compact footprint. For engineers and operators, the project has brought new energy and excitement. “There’s been a really strong level of engagement from our engineers,” said White. “They’ve embraced the new technology, enjoyed gaining hands-on experience with the packaging machine, and worked closely with the installation team. It’s definitely the way forward. This next generation of robotics is going to play a huge part in the future of all businesses.”

“The key is engaging people properly with an automation project,” Adele Davies added. “When you do that, they see the excitement in it and recognise how it can enhance their jobs. People say, ‘We’ve got robots now,’ and they genuinely enjoy it. This project is just the beginning, the first of many more to come in the future.”

Bagnall concluded: “It’s a very flexible machine that we can tailor to almost any end user’s requirements. As OMRON’s technology continues to evolve, we need to evolve with it so that we can keep delivering more solutions for our customers.”

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You’ll be able to see how OMRON’s customised automation solutions improve production speed and precision, while accommodating various bottle sizes and shapes.

To be held at the National Exhibition Centre (NEC), Birmingham, from 23-25 September, PPMA 2025 is the UK’s largest event for the processing equipment, packaging machinery, industrial robots, and machine vision system sector. Thousands of visitors are expected to attend, to see cutting-edge solutions from more than 350 exhibitors, listen to multiple free talks from industry experts, and make the most of countless networking opportunities.

OMRON has arranged a packed schedule of demonstrations across the three days of the show, all designed to help organisations overcome the practical challenges of embracing the future of manufacturing, today.

Stuart Coulton, marketing manager UK&I, said: “Digital enablement is about making factories and processes more efficient. Yet while the technology, and its potential, is evolving fast, adoption is not always straightforward.

“At PPMA this year, we want to help our customers understand how to put theory into practice. That’s why we will be showcasing the power of condition-based monitoring, demonstrating easy-to-scale sensor technology, and explaining how to overcome the biggest challenges to implementation: bridging the gap between IT and OT, and combatting data overwhelm.”

OMRON will be based at stand B34, where highlights will include a demonstration of the power of sensor-driven technology. Join the team to learn:

• how sensor-driven technology can provide the framework for condition-based monitoring, helping factories to avoid unplanned downtime and extend the life of equipment;
• how installing even a small number of sensors in the production line can generate the data facilities need to drive efficiencies and productivity;
• how to collect, analyse, and use sensor data to guide production decisions;
• how to rationalise and optimise sensor use;
• how to bridge the gap between IT and OP functions.

In addition, the stand will also showcase a range of OMRON’s industry-leading solutions:

• VHV5 code reader: This advanced code reading technology offers rapid set up and high-quality, high-resolution imaging, as well as a code grading system that enables operators to detect printer degradation ahead of time;
• NX5 controller: OMRON’s visual inspection and automated playback can detect defects in uniform background objects, enabling automatic, human eye-like quality control without complicated set up;
• Digimarc digital watermarking: Prevent mismatched components and mislabelled products with digital watermarking, increasing production speed and efficiency while streamlining the distribution and fulfilment of packaged goods;
• Sysmac Studio:  The first industry integrated development environment, bringing logic, motion, robotics, human-machine interface (HMI), vision, sensing, safety and 3D Simulation into one single platform.

The OMRON team will also be on hand throughout to provide information and answer questions about the company’s products – and their role in the future of manufacturing.

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This is the second time one of OMRON’s permanent facilities has been honoured with an iF Design Award. The first was awarded in 2021 to the Automation Centre in Tokyo.

The iF Design Award is one of the most respected design competitions worldwide, established over 70 years ago. It is judged by an independent panel of experts, who assess thousands of entries each year based on criteria such as functionality, user experience, sustainability, and relevance to current societal and industrial challenges. In 2025, the jury evaluated around 11,000 submissions from 66 countries.

Opened in April 2025, OMRON’s Automation Centre Stuttgart was designed as a collaborative environment where customers can explore new approaches to factory automation. The facility offers a space to jointly develop and test solutions that address specific manufacturing needs, with a strong focus on practical application and regional relevance.

The jury recognised the Automation Centre for its architectural clarity, its purposeful design in support of co-creation, and its integration of sustainable principles. The facility makes conscious use of recyclable materials and equipment sourced from local suppliers where possible, contributing to reduced environmental impact. The design also supports a flexible and functional layout, enabling efficient workflows for innovation in manufacturing.

With 48 Automation Centres and Proof-of-Concept labs worldwide, OMRON supports customers in developing solutions tailored to their local needs and industries.

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Through this new organisation, OMRON is further investing in the long-term success of its customers, by ensuring quick decision-making and world-class technical support, as well as strengthening its specialised expertise across Europe. The investment also comprises OMRON’s Automation and Robotics Centres of Excellence in Annecy, Barcelona, Dortmund, and the newly opened Automation Centre in Stuttgart, and an extensive network of Proof of Concept (PoC) labs that support local customer innovation.

The specialised organisation in Europe consists of a dedicated, passionate team of sales, application, and services engineers. They will operate at both European and country level, and work closely with the global robotics organisation. The new setup will enhance targeted technical expertise, whilst allowing OMRON to respond even faster to evolving customer needs.

“Robotics plays a vital role in our vision for the future of automation. This investment reflects our strong focus on building expertise, quality of service, and helping our customers stay competitive,” said Fernando Colas, CEO of OMRON Industrial Automation EMEA. “We are putting the optimal structure in place to ensure continued excellence in innovation and customer satisfaction.”

“I’m excited to kick off this new initiative, which is all about helping our customers get the most out of their robotics investments,” said Vincent Nabat, General Manager of OMRON Robotics EMEA. “With a dedicated robotics organisation, we’ll be able to respond faster to local needs, offer more direct access to technical expertise, and collaborate even more closely with our customers on co-development projects with fixed, mobile and collaborative robots.”

The new organisation also strengthens ties with OMRON’s global R&D and robotics teams, alongside the newly established European R&D team. This supports faster innovation and the delivery of solutions that are closely aligned with the specific needs of European customers.

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Strategically located near key customers and partners, the new facility serves as a hub for expertise in advanced automation solutions. It enables true co-creation, proof-of-concept development, and hands-on collaboration.

The OMRON Automation Centre Stuttgart joins a global network of 48 Automation Centres and Proof-of-Concept labs to support customers and partners across Germany and Europe. Spanning 2,372 m2, and located just minutes from the Stuttgart international airport, the facility is home to a team of experts in industry-specific solutions, including sensing, control, vision, safety, robotics and AI-driven technologies. By actively co-developing solutions with customers, OMRON helps manufacturers, machine builders and system integrators tackle key societal challenges, such as labour shortages.

Fernando Colas, CEO at OMRON Industrial Automation Europe comments: “This new Automation Centre in Stuttgart represents our significant investment in Germany and in the EMEA region. I am incredibly proud of the dedication and teamwork that made this vision a reality. Seeing this project come to life and now standing in a space where we can innovate together with our customers is an inspiring moment. We are excited to shape the future of manufacturing together with our customers and partners.”

Peter Ehl, General Manager at Automation Centre Stuttgart concludes: “At OMRON, we believe that the best innovations emerge through collaboration. What makes this Automation Centre so special is that it was purpose-built from the ground up specifically for OMRON. Every part of this facility has been designed with our customers in mind – to provide an environment where we can collaborate, test, and refine real-world automation solutions.”

The new facility aligns with OMRON’s long-term vision to drive innovation and continue to contribute to the development of society. OMRON is dedicated to supporting its customers with innovative, scalable, and flexible solutions that drive operational excellence in manufacturing.

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As we step into 2025, the world of industrial automation is approaching a new chapter. According to OMRON’s SINIC Theory, which ties technological advances to societal change, we’re now moving from the Optimisation Society to the Autonomous Society.

The theory, created in 1970 by OMRON’s founder Kazuma Tateishi, predicts future societal and technological developments to guide innovation. In the Optimisation phase, the focus has been on refining processes, boosting efficiency, and using technology to improve operations. But the Autonomous Society is a whole new era – one where systems don’t just run efficiently; they become self-regulating, self-learning, and capable of independent decision-making.

With that in mind, let’s explore the top five trends that OMRON believes will shape the future of industrial automation in the coming years.

Smarter maintenance and data-driven automation

One of the most transformative trends for the industry is smart or predictive maintenance, enabled by data-driven automation. This shift allows for proactive responses to equipment wear and tear, reducing downtime and enhancing overall operational efficiency.

Data-driven automation is not only about identifying when something will go wrong but also using that data to optimise production processes. In OMRON’s vision, “Sensing & Control + Think” brings together advanced sensors, control technologies, and data analytics to enable systems that can learn from their environment, making adjustments to improve efficiency and productivity autonomously. This technology is a cornerstone of the shift to autonomous production, where real-time data from sensors and machines drive decision-making.

Adaptive systems for smart manufacturing

As manufacturing environments become more complex and diversified, traditional control systems are no longer sufficient. Smart manufacturing environments demand adaptive control systems that can respond dynamically to changing conditions. OMRON has already developed AI-driven control systems that integrate real-time data to adjust machine parameters dynamically, improving production quality and consistency.

In sectors such as semiconductor manufacturing, where precision is critical, OMRON’s high-resolution inspection systems, such as the VT-X950 with advanced X-ray and CT scanning, can detect defects at the micro-level in real-time. This enables manufacturers to immediately correct errors, significantly improving yield and reducing waste. These adaptive systems represent the future of quality control in manufacturing, where machines continuously monitor and adjust themselves for optimal performance.

Co-creation as a driver of innovation

Co-creation with partners, customers and academic institutions are key drivers of innovation in industrial automation. This approach cultivates innovation within the company’s own ecosystem but also by pooling insights and capabilities from external partners. Collaboration with external partners and other business units allows for the creation of services that enhance both our products and broader societal solutions. This is not limited to typical business collaborations; OMRON’s reach extends to efforts like the ‘Health and Productivity Management Alliance’, where various companies, including OMRON, come together to address significant healthcare challenges and create data-driven solutions.

Co-creation drives faster technological development and ensures that the solutions developed are closely aligned with the needs of the market and society. For example, next-generation technologies accelerate material innovation by predicting the properties of new materials based on their molecular structures. Through collaborations with research institutions and universities, OMRON is creating new opportunities for innovation that would be impossible within the confines of a single organisation.

Energy efficiency through smarter product and component design

Industries are facing increasing pressure to reduce their environmental footprint. Traditional silicon-based power devices have long dominated industrial systems, but they come with limitations in efficiency and size. OMRON’s investment in GaN (Gallium Nitride) technology addresses these challenges by delivering high-performance power conversion with minimal energy loss.

GaN devices allow for greater power handling capabilities within a much smaller footprint, resulting in miniaturised components that require less energy to operate while also cutting down on heat generation. This is especially interesting for industries like automotive manufacturing, where lighter, more energy-efficient components are essential for the production of electric vehicles (EVs).

Ethical AI and transparent decision-making

As AI becomes more embedded in industrial systems, ethical considerations around its use are gaining importance. In manufacturing, this means creating systems where AI-driven decisions can be audited and understood, ensuring that companies maintain control over their operations while benefiting from the efficiencies that AI brings. Ethical AI is expected to play an increasingly important role as factories become more autonomous. Ensuring transparency in AI decision-making will be critical to maintaining trust between companies, employees, and stakeholders.

As we move further into the Autonomous Society, the way we approach industrial automation is fundamentally evolving. Predictive maintenance, adaptive control, and co-creation are realities reshaping manufacturing today. With every innovation, from real-time data analytics to advanced material science, we’re not just improving processes – we’re enabling systems to think, learn, and act on their own. Together, we need to build smarter, more resilient manufacturing systems for a complex, ever-changing world.

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With a payload capacity of 25 kg and a 1900 mm reach, the OMRON TM25S is a perfect solution for palletising, mobile manipulation and even welding applications. Its compact design and low weight of just over 80 kg make it easy to integrate into existing workflows, whether for end-of-line material handling or advanced machine tending. The available DC power option allows for seamless mobile robot integration without the need for a secondary power source.

Key advantages of the TM25S include its built-in optional vision system, which simplifies tasks such as package identification and part inspection. Additionally, its enhanced joint covers offer protection against harsh environments, making it suitable for a wide range of industrial applications.

Like all OMRON cobots, the TM25S is designed for collaboration, with no need for a safety zone, ensuring smooth and safe operation alongside human workers. Its space-efficient design maximizes workspace while offering flexible, high-performance automation.

The OMRON TM25S is certified to the highest industry standards, including ISO and UL safety certifications, ensuring reliable and safe operation across a range of industries.

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