Most US manufacturers have tried AI and automation but few see clear returns. AI can combine human experience with machine data to spread expertise across a plant. It can cut downtime, speed troubleshooting and reduce reliance on a few experts. Plant managers say AI supports people rather than replacing them. Many firms run small pilots instead of full rollouts. Pella uses cross-functional teams to develop, analyze and scale AI solutions. Experts warn against rushing into AI without defining the problem it solves. Chemical plants face safety risks if AI is implemented poorly. Plant managers struggle with the expectation to become AI experts overnight. Most AI projects fail because they do not fit how the plant actually works. Companies now spend more on human capital to implement AI correctly.

• 95% of AI pilots show no measurable impact
• 90% of AI projects fail in first year