Düsseldorf 2026 Recap: Why AI Projects Need Context

Almost 80% of AI projects in manufacturing never reach production. That is what our live survey shows, and what we heard again at the Düsseldorf booth. Here is why it happens, a 10-minute test, and five real cases from the fair.

The Numbers: What Our Live Survey Shows

23%

of AI pilots reached production

21%

AI projects did not solve the problem

32%

Fully successful projects

On average, companies ran 2 proofs of concept last year, but only 23.1% reached production - the rest disappeared into the “Bermuda Triangle” of feasibility studies. In October 2026, 21% said they use AI that has not helped (earlier surveys: 0 to 8%), and fully successful projects dropped from 58% (September 2025) to 32%.

Why it Happens: AI Without Context

In this talk in the Talk Lounge, Philip Privalov put it simply: AI is rarly the problem. What projects lack is meaning and data context. A signal like State = 4 is worthless as long as the system does not know which machine and which state it refers to. 

The 10-minute Test for Your AI Project

We call it the Monday Morning Test. Go through these five questions. If even one stays open, your next step is not the AI model but the machine-readable data basis.

German Slides (PDF)

1. Goal

What exactly should the AI improve?

2. Data

Which data does it need, and do you have it?

3. Meaning

Does the system know what each signal means? 

4. Context

Does it know which machine and which state?

5. Action

Who does what with the answer?

Five Real Cases from the Booth

Different industries, the same question: how do we get value from our data? Open the cases that sound like your situation. 

An interim manager told us about an AI system he had tested. Without real production context, it concluded that the best way to avoid errors was for the line to stop completely, which is logical for the model, but not in practice. 

What this means for you: If your AI tool does not know your process, its answers will not fit your line. 

Visitors from India and Morocco made it clear: data-driven machine optimization is no longer a privilege of high-wage countries. Efficiency and transparency are now key to competing globally. 

What this means for you: Your competitors abroad are digitalizing too, so waiting is the bigger risk. 

A well-known premium manufacturer needs a concept for highly automated assembly by year-end. For gluing and riveting, capturing process data and quality parameters from the very first second is decisive. 

What this means for you: Plan data capture together with the line, not after it, because adding it later costs more. 

A filtration technology manufacturer with mainly manual workstations wants to start with Manual Data Input (MDI). It gives them a reliable data basis for planning later automation steps. 

What this means for you: You don't need automation to start; manual data entry gives you a baseline today.

A builder of special machines wants to show measurement curves directly on the machine because their current system falls short. Shopfloor Software gives operators that transparency on the line. 

What this means for you: Operators decide faster when they see the data they need.

Check Your Project with Us

Took the test and found an open question? Bing it to a short call - we will look at your use case and your data together. 

Schedule an Appointment

Schedule an Appointment

Roland Schmalzer
Business Development
STIWA Software
Portrait Philip Privalov

Schedule an Appointment

Philip Privalov
Head of Business Development
STIWA Software

A Look Forward

Event

SPS 2026

Join STIWA at the SPS Fair 2026 | 11.24.2026 9:00 - 11.26.2026 16:00 | Nuremberg, Germany | Hall 6-239

SPS Fair

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