Manufacturing Software Engineering: Agile Meets Hardware
A mid-sized automotive supplier I consulted for in 2024 had a production bug land at 03:15 on a Tuesday. The fix took 8 minutes to code and 19 days to deploy — because it required a software update to PLCs on 14 production cells, each of which could only be updated during the 4-minute changeover window between shift batches. The engineering team's average lead time on the office-IT side: 31 hours. On the shop-floor side: 14 days. Same team, same repository, two different universes of delivery constraint.
Manufacturing software engineering is Agile meeting hardware. The practices that work at a SaaS startup — deploy-whenever, feature flags, canary releases — collide with regulated plant-floor reality: OEE targets, changeover costs, OT/IT separation, and production lines that cannot pause for a deploy. A 2023 Deloitte Smart Factory study found 73% of manufacturers cite "IT/OT integration" as the top barrier to digitization. The problem isn't technology; it's that metrics and rituals designed for pure software break when the software touches a physical process.
