According to recent Columbus research, 56% of manufacturing IT leaders say system integration is their top challenge. But, it’s not just a technical issue. Fragmented systems create costly inefficiencies, limit visibility and slow down decision-making on the shop floor.

Here’s the good news: modernization doesn’t always mean ripping out legacy systems. In fact, the smartest path forward is often about making old and new work together.

Rethinking Modernization: It’s Not All or Nothing

Manufacturers don’t operate in greenfield environments. Legacy ERP platforms, custom-built MES and siloed databases are deeply embedded in day-to-day operations. They’re familiar, reliable and often irreplaceable. But they weren’t designed to talk to cloud-native tools or power advanced analytics.

That’s where the integration gap emerges. Bridging it isn’t about a single overhaul. It’s about designing an architecture that allows legacy and modern systems to coexist, share data and create a foundation for scalable innovation.

So, how can manufacturers close the integration gap? Here are three practical approaches:

1. Middleware: The Unsung Hero of Integration

Middleware often serves as the first bridge between legacy systems and new applications. Think of it as the connective layer that translates and transmits data between older ERP platforms and modern cloud tools. For manufacturers that depend on legacy infrastructure to keep production running, middleware offers a non-disruptive way to modernize. It allows these core systems to interface with newer technologies without requiring a full rip-and-replace overhaul.

The beauty of middleware lies in its flexibility. It enables interoperability across disparate systems, reduces data silos and improves data synchronization creating a more unified digital ecosystem. Middleware also makes it easier to scale, giving manufacturers room to add new tools or capabilities over time. Still, it’s not without challenges. If poorly managed, it can introduce complexity or latency, especially in environments lacking strong data governance. That’s why a clear integration strategy, backed by well-defined data standards, is essential for long-term success.

2. Low-Code and No-Code: Speed Meets Flexibility

While middleware is great for connecting systems, low-code and no-code platforms are redefining how quickly those connections can be built. These tools enable both IT teams and business users to create applications, dashboards and workflows using drag-and-drop interfaces and minimal code. In manufacturing, where time is money and IT resources are often stretched thin, low-code platforms accelerate development cycles and reduce reliance on specialized developers.

What makes low-code so powerful is its accessibility. A plant manager can build a real-time inventory tracker, or a quality engineer can automate data collection without having to wait in line for IT support. This decentralizes problem-solving and allows innovation to happen closer to the front lines of production. Low-code platforms are especially valuable for small and midsize manufacturers that need to move fast but lack the budget for fully custom development. When done right, they enable a more agile, responsive business without compromising control or oversight.

3. Data Governance: The Foundation That Holds It All Together

Even the best integration tools will fall short without clean, consistent and accessible data. In legacy environments, data often lives in multiple formats across siloed systems, riddled with inconsistencies and duplicates. That makes integration difficult and risky. AI, analytics and automation tools rely on trustworthy data to deliver results. Without proper governance, these systems can’t operate at full potential.

Improving data governance starts with a foundational step: a thorough data audit. Manufacturers need to understand what data exists, where it resides and how it flows across systems. From there, they can begin to standardize formats and definitions, aligning units, naming conventions and structures to ensure compatibility. The next step is technical—using APIs or middleware to facilitate integration across platforms. But governance is also about people. Assigning data ownership roles ensures ongoing accountability and helps maintain integrity over time.

Building a Roadmap to Smarter Integration

There’s no single “right way” to modernize, but in general it’s best to start with a clear understanding of current systems, choose the right integration approach based on specific needs and don’t try to go it alone.

Start by assessing the current IT stack to identify what’s working, what’s holding it back and what it really needs. Many legacy systems still have untapped potential. A careful review may reveal opportunities to optimize existing platforms before pursuing replacements.

If the internal team is overwhelmed, or if integration challenges go beyond their expertise, it’s time to call in outside help. Consultants can fast-track modernization, especially for complex ERP environments or large-scale data projects. In fact, more than half of IT leaders in the Columbus study say they’re open to engaging external firms in 2025. Look for partners who understand manufacturing workflows, not just tech. Domain expertise is just as important as coding skills when it comes to designing solutions that actually work on the shop floor.

System integration may be the biggest hurdle manufacturers face, but it can also be one of the most rewarding. Bridging the old and new is about practical solutions that drive real outcomes.