Harnessing the Untapped Knowledge of Your Front-Line Workers to Fill Gaps in Technology Investments

From the steam-powered engines of Industry 1.0 to the AI-enhanced assembly lines of Industry 4.0, manufacturers have experienced significant advancements aimed at improving quality, minimizing waste, and reducing production times and costs. As we transition to Industry 5.0, the focus is now on creating a more connected factory environment where human-centric approaches redefine workforce engagement and productivity.

Manufacturers today recognize the urgency of digital transformation, with 87% of senior business leaders stating that digitalization is a company priority. However, only 40% of organizations have successfully scaled their digital initiatives. According to data from PwC, 60% of senior executives believe that digital transformation will be critical for business growth. This sentiment is echoed by a study from the Digital Marketing Institute, which reveals that 1 in 3 companies view digital transformation as a matter of survival.

As the manufacturing sector evolves, embracing the concept of the Industry 4.0 Connected Worker becomes increasingly vital. CEOs report significant benefits from digital initiatives, with 56% indicating that their digital improvements have already increased profits. In comparison to competitors, companies adopting digital-first strategies are 64% more likely to achieve their business goals. Moreover, research shows that digitally mature companies are substantially more likely to generate revenues exceeding $1 billion compared to their less digitally advanced counterparts.

The necessity for digital transformation is clear, as it has the most significant impact on operational efficiency (40%), time to market (36%), and customer satisfaction (35%). Additionally, McKinsey reports that investing in digital transformation and enhancing customer experience can lead to increases in customer satisfaction by 20-30% and economic gains by 20-50%.

As such, manufacturers must prioritize leveraging advanced technologies and strategies in their ongoing journey toward becoming Industry 5.0 leaders.

Before hopping on the industry 5.0 bus, it's essential to understand where it will take your operation and whether the timing is right. Prior to investing heavily in artificial intelligence, consider harnessing the real intelligence of your frontline workers.

Your Frontline Workers Are Knowledge Workers

As we progress toward a paperless factory environment, we've automated many tasks within the production line, transferring responsibilities from workers to machines. For example, quality checks once carried out by skilled workers are now performed by advanced cameras and computers, while repetitive machining tasks are executed by robots equipped with sophisticated tools.

However, it's crucial not to overlook the unique contributions that frontline workers make to the production process - elements that machines cannot replicate.

The tasks we have automated were previously performed by human workers who possessed in-depth knowledge of these processes. More importantly, these individuals offer vital soft skills - traits such as empathy, communication, critical thinking, creativity, strategy and vision - that enhance overall workforce productivity in a connected factory setting. According to Forbes, these "Skills of the Future" are inherently human traits that machines will never fully emulate. Consider the following situations that emphasize the importance of knowledge workers:

Quality Control: In production runs, seasoned operators can identify potential issues before they result in costly shutdowns. An automated system might only alert users after subpar products have been produced.

Problem Resolution: In an unplanned stop, automated systems can identify where an issue occurred but may struggle to diagnose the root cause. An experienced operator can creatively assess the situation based on experience and identify effective solutions that a machine might overlook.
Preventive Maintenance: While automated systems specify actions needed during scheduled maintenance, skilled operators can evaluate ongoing conditions as part of the task and proactively address additional issues that could help avoid future downtime.

It's critical to recognize that frontline workers are indeed knowledge workers. Seeing them merely as low-skilled laborers to complete repetitive tasks undervalues their contributions. They possess practical experience and deep insights into operational challenges, knowledge that is essential for continuous improvement.

Unfortunately, this valuable information often remains unshared, stored in the minds of workers who are rarely consulted or asked. Amidst the excitement surrounding IoT and AI, we have often failed to invest in technologies that support these vital employees effectively.

The Missing Piece to Empower Workers

While many industries empower their knowledge workers with productivity and collaboration tools, the factory floor has lagged in implementing new technologies to support worker knowledge for years. Many factory workers still rely on outdated methods to access the information and resources they need daily, relying on printed documentation and verbal communication.

It's both ironic and disheartening to see workers beside advanced, robot-controlled and AI-powered assembly lines still holding binders filled with printed work instructions or posting notes on multi-million-dollar machines to ensure the next shift sees them. Consider these familiar challenges:

Outdated Documentation: Workers may neglect documentation that is difficult to access or not up to date, leading to inconsistent work processes and reliance on colleagues for information.

Delayed Information: Critical updates and troubleshooting information often take too long to reach workers, leading to prolonged downtime and reduced productivity.

Knowledge Drain: Experienced workers who retire often take invaluable tribal knowledge with them, resulting in the loss of insights and millions invested in their professional development.

These issues highlight the need for a comprehensive solution like Poka to digitally connect your frontline workers.

Digitally Connecting Your Frontline Workers

Recognizing the value of your front-line workers leads to the development of effective connected worker solutions. Industry leaders, including Mars, Danone and Bosch, are empowering their employees with digital performance support applications, such as Poka, to address these challenges and facilitate their digital transformation journey.

To define a successful connected worker solution, consider the following elements:

Accessibility of Digital Work Instructions: Workstations should be equipped with tablets enabling workers to digitally access all the information they need, from standardized work instructions to troubleshooting guides.
Real-Time Communication: Implement tools that allow workers to communicate seamlessly across production lines, shifts, and plants. This capability fosters knowledge sharing and promotes collaboration.
Performance Support: Create a user-centered interface that integrates digital content and communication, ultimately improving workforce productivity and enhancing the workforce experience in a connected factory.

With Poka’s app, workers can scan QR codes on their equipment or work orders using tablets to access the most current updates and work instructions. This technology promotes seamless communication across production lines, shifts, and even different plants, enabling them to troubleshoot problems, share knowledge and learn from one another.

By providing accessible information and communication, organizations can help workers align with industry standards, bringing these standards to life as useful tools for daily operations.

Proven Efficiency Gains in Smart Manufacturing

By digitally connecting their workforce and granting instant access to necessary tools and resources directly at their workstations, manufacturers have experienced remarkable efficiency gains.

For example, leading chocolate manufacturer Barry Callebaut reported a 4% increase in productivity at one of their Canadian plants, along with a reduction in training time by 50%. "Our expectations have been exceeded in every respect," noted John Schouten, Director of Global Operational Excellence. "We will now progressively roll out the system worldwide."

Similarly, Nutricia N.V., a division of Danone, achieved a dramatic 75% reduction in the time required to set up new skills, along with a 40% decrease in shadowing time. "Operators take the lead in their own learning. They learn when they need to, the right way, and without constantly interrupting other operators' work," explained Jorn Vroegh, Learning and Development Coordinator.

Find a New Way to Empower Your Workers Today

The transition to Industry 5.0 is underway. Now is the time to join this exciting movement by equipping your workforce not only with essential tools but also by fostering an environment in which they can thrive.

As we pave the way for a connected factory and a successful transition to Industry 5.0, let's empower our human workforce and tap into their invaluable insights for a more innovative and productive future in manufacturing.

To learn more about how Poka can help implement a digital transformation strategy in your factory, visit our website and watch our 2-minute video showcasing the success stories of Tyson Foods, Mars, and others who have embraced smart manufacturing principles.

The Role of the Connected Worker in Total Productive Maintenance

This article was updated in November 2024 for accuracy.

Empowering vs. Replacing Workers in the Move to Industry 4.0