Despite a surge in digital investment across engineering, procurement and construction (EPC) sectors, many organisations continue to struggle with realising the full value of their transformation efforts.
Hexagon’s recent Digital Thread report reveals a persistent gap between the adoption of digital tools and the return on investment (ROI) they deliver. The culprit? Fragmented systems, manual processes and a lack of platform-based thinking.
According to Hexagon’s global survey of 400 industrial leaders, 70 per cent of organisations have increased their digital toolsets in the past year. Yet 56 per cent admit that these efforts have not yielded the expected value. In fact, 63 per cent of those with more tools than a year ago say their teams spend excessive time manually creating reports and consolidating data, equating to 117 working days per year.
This paradox highlights a critical issue: more tools do not necessarily mean better outcomes. When digital solutions operate in silos, they create inefficiencies, hinder collaboration and obscure visibility across the project lifecycle. The result is missed milestones, budget overruns and unplanned downtime; challenges that 75 per cent, 67 per cent and 65 per cent of surveyed leaders respectively report as having a strong or severe impact.
To bridge this gap, Hexagon advocates for a shift from point solutions to platform-based architectures. Solutions like EcoSys™ and Integraph Smart® Completions are designed to unify data across disciplines and projects, enabling real-time insights, reporting and contextualised decision-making. These platforms act as a digital backbone, supporting the continuous flow of information, which Hexagon defines as the “digital thread”.
The digital thread connects data from engineering to operations, to preserving context and ensuring continuity. Organisations that frequently use digital thread technology report significantly better stakeholder access to critical data, 71 per cent compared to 57 per cent among less frequent users. This visibility is essential for aligning teams, reducing risk and accelerating project delivery.
For example, CPB Contractors (JHCPB), in a joint venture with John Holland, used Hexagon Smart® Completions to design and construct the Rozelle Interchange and Western Harbour Tunnel Enabling Works in Sydney. JHCPB’s overall objective was to harness a completions solution that would enhance productivity and efficiency, streamline processes, and guarantee the integrity of the finished project.
The JHCPB team estimates that around four hours were saved each week simply by having the tasks linked to automated reports that could show the project’s real-time status. This enhanced productivity and visibility at all company levels.
Hexagon’s report also outlines five best practices for advancing digital thread maturity. These include addressing legacy systems, planning for scalability, choosing adaptable solutions, adopting platform thinking and leveraging AI once foundational data integrity is achieved. Each step is designed to ensure that digital investments are not only technically sound but strategically aligned with long-term business goals.
In an era where infrastructure projects are increasingly complex and data-rich, platform thinking is no longer optional; it is essential. By moving beyond fragmented tools and embracing integrated solutions, EPCs can unlock the true potential of digitisation, deliver measurable ROI and build resilience for the future.
Learn more about Hexagon Digitalisation for Industrial Projects solutions. Download the Digital Thread Report | – Data Connectivity & Visibility | Hexagon or view the Rozelle Interchange case study: Intergraph Smart® Completions Enabled Rozelle Interchange to Deliver a Quality Product on Time
