The Human–Technology Gap in Modern Automotive Manufacturing
The shift toward digital, software-defined automotive production has widened the gap between engineering education and real factory floor demands. As an automation engineer, I see how modern plants now require an integrated skillset combining PLC logic, networking, data analysis and cybersecurity—competencies that traditional programmes rarely address.
Rockwell Automation and Toyota Motor Manufacturing UK (TMUK) have built a training model specifically engineered to close this growing divide.
A New Training Blueprint at Toyota Burnaston
Toyota’s Burnaston Academy blends two years of structured classroom learning with two years of shop-floor deployment. What makes the programme stand out is its commitment to teaching automation using the same generation of Rockwell hardware and software used in real plants.
In my experience, this philosophy is vital. Training on outdated systems leaves new engineers unprepared for the complexity and digitalisation they will face on day one.
Why Real Factory Hardware Is Essential
Stephen Heirene, Industry Consultant for Transport and Future Mobility at Rockwell Automation, emphasises that hands-on exposure is indispensable. I fully agree—automation is ultimately a physical trade.
Understanding wiring layouts, fieldbus behaviour, HMI logic flow and safety circuits requires genuine tactile interaction.
Training on modern PLCs gives engineers the conceptual clarity needed to both manage new systems and troubleshoot legacy ones.
Future Mobility Broadens the Skill Landscape
Heirene’s role spans electrification, hydrogen systems, autonomous technologies and new mobility ecosystems. As these domains expand, engineering roles are becoming more interdisciplinary.
From my perspective, today’s automation engineers must combine:
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classical controls theory
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network architecture literacy
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data analytics awareness
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safety compliance knowledge
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and software-centric problem solving
Rockwell’s industry-specific organisational model ensures that its teams stay aligned with these shifting technical demands.
A Scalable, Multi-Channel Training Ecosystem
Rockwell supports upskilling through a robust framework:
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classroom training at Milton Keynes
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virtual Learning+ modules (300+ packages)
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instructor-led remote courses
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competency assessments and roadmaps
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hardware training rigs
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Emulate3D simulation with physics and VR
From my engineering background, the combination of real hardware and emulation is particularly powerful. Simulation teaches concepts; hardware teaches instinct and applied judgement.
Preserving Institutional Knowledge Before It Disappears
Toyota’s model leverages retiring technicians as instructors and mentors—a crucial strategy in an industry facing accelerating knowledge loss.
Rockwell complements this with structured TÜV-certified training for machine safety and advanced competency validation.
The blend of seasoned insight and modern digital tools produces engineers capable of bridging generations of technology—an ability increasingly crucial in brownfield environments.
Networking: The New Critical Competency
Modern factories operate as interconnected digital ecosystems. PLCs, HMIs, sensors, MES, PLM and ERP layers share data across complex networks.
This means that an engineer’s ability to diagnose problems often depends more on understanding EtherNet/IP traffic, VLAN segmentation, OPC UA behaviour or firewall rules than on pure ladder logic.
I strongly agree with Heirene’s view that networking will dominate future skills development. It is becoming the backbone of every smart factory.
Supporting Start-Ups and Legacy Manufacturers Differently
Rockwell adapts its approach depending on manufacturer maturity:
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Start-ups need full-stack support—from network design to MES, PLM, ERP and digital thread creation.
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Legacy plants need hybrid training that strengthens skills for both older systems and next-generation technologies.
Engineers entering the workforce today must be fluent in both worlds—a dual competency that academies like Burnaston are uniquely positioned to cultivate.
Looking Ahead: Training for Constant Technological Evolution
Electrification, battery production, autonomous systems and AI-driven manufacturing will continue to reshape the automotive industry.
Training must not only stay current but anticipate future requirements.
In my professional view, adaptability is becoming the most valuable engineering skill. The engineers who thrive will be those who can quickly absorb new tools, new systems and new digital workflows throughout their careers.
Rockwell and Toyota’s collaborative training model provides a blueprint for how the industry can prepare for this continuous transformation.
