The manufacturing sector has come a long way in 236 years. It has changed from using steam machines to modern production lines that use robots and artificial intelligence. Despite the progress, many factory workers still use outdated technology to find important information and learn how to use newer machines. This disconnect poses significant challenges to productivity and employee satisfaction, particularly in an era of Industry 5.0, digital transformation and smart manufacturing.

Today’s fast-paced production requires that factory workers have the right tools, information, and support to keep everything running smoothly. Companies should not rely only on paper and talking. They need to invest in tools that help employees do their jobs better. These tools make communication easier, improve training and create a more engaged and productive workforce.

Here are 10 signs that your factory is ready to help workers with better support systems:

1. Outdated Standard Operating Procedures (SOPs) Are Impacting Worker Performance

Operators often perform below standards because printed Standard Operating Procedures (SOPs) are outdated or stored in hard-to-access locations away from their workstations. Inaccessibility could result in misunderstandings and inefficiencies on the manufacturing floor, as employees cannot consult the most recent procedures and methods.

In a smart production environment, it's important for workers to quickly get the latest SOPs online to do their jobs well. Leveraging the power of Industrial AI, Poka can seamlessly convert not only text-based SOPs but also other formats like PDFs, images and videos into standardized digital work instructions. This versatility allows manufacturers to integrate a variety of content types into a single platform, streamlining access to critical information.

By utilizing AI-driven tools, these formats can be automatically parsed, translated and organized ensuring that frontline workers have immediate access to the most up-to-date instructions, no matter how the original content was created. This adaptability not only optimizes workflow efficiency but also enhances knowledge retention and training capabilities across multilingual teams.

2. Slow Communication of Important Updates is Hindering Workforce Productivity

Frontline workers often receive important updates too late, as they are conveyed through hand delivery or spoken directions. This inefficiency can result in missed information, which may lead to operational delays. In a connected workforce, rapid and effective communication is crucial. Implementing digital communication tools ensures that all team members receive real-time updates, significantly decreasing the time required to convey essential information. By enabling swift communication, manufacturers can enhance productivity and foster a culture of responsiveness among their teams.

3. Inefficient Troubleshooting Processes Are Affecting Manufacturing Efficiency

Fixing problems in manufacturing can take a lot of time, sometimes hours. This is because workers often can't easily get to share knowledge or find specialists who can help them right away. Efficient problem-solving is critical to minimizing downtime and maintaining seamless operations. A connected worker app that helps workers do better can be a place to share information. It lets workers work together and get expert help right away.

By improving troubleshooting processes, organizations can reduce response times significantly, improving operational efficiency and ensuring that production targets are met consistently.

4. Unresolved Issues Are Diminishing Employee Morale and Productivity

Unresolved issues can linger for months because they are forgotten or brushed aside. This affects productivity and severely impacts employee morale. An effective connected worker support system can help track and resolve issues promptly through automated reminders and accountability mechanisms. A structured approach to issue resolution ensures that challenges are addressed in a timely fashion. As a result, workers feel more involved and excited. They feel like they are part of a workplace that appreciates what they do and promotes open communication.

5. Missing Contextual Information is Reducing Problem-Solving Capabilities

While pinpointing the core issue of a problem, simply possessing system data that validates the occurrence is not adequate; comprehending the situation surrounding the problem is equally vital. Without this contextual information, implementing effective corrective actions becomes a challenge.

Using digital job guides and learning materials helps workers understand why things are done a certain way. This improves their decision-making skills. As a result, they can solve problems better and produce higher quality work on the factory floor.

6. Ineffective Continuous Improvement Initiatives Are Hindering Workforce Engagement

Initiatives for continuous improvement can become stagnant when employees perceive the sharing of their ideas as burdensome or become disenchanted with the process. Cultivating a culture of continuous improvement requires an environment where workers feel empowered to contribute. An app designed for performance assistance can provide a convenient platform for employees to submit their suggestions effortlessly, allowing them to see their contributions being appreciated and implemented. Engaging workers in continuous improvement efforts can drive innovation, foster a sense of ownership among employees and elevate overall operational excellence.

7. Loss of Tacit Knowledge is Impacting Operational Continuity

With the annual retirement of experienced employees, crucial institutional knowledge - built over years of practice and understanding - is departing the company, leading to notable deficiencies in skills and proficiency. This loss can hinder productivity and continuity in operations. Digital performance support solutions can play a critical role in preserving this knowledge.

By systematically documenting best practices and processes, organizations create an accessible knowledge base for incoming employees. This helps ensure continuity in operations, performance and quality as workforce dynamics change.

8. Lack of Real-Time Skills Coverage Visibility is Challenging Workforce Planning

Many organizations struggle to maintain real-time visibility into skills coverage because they depend on outdated methods like spreadsheets. This limitation makes it hard to plan for workers and assess their skills.

By adopting a worker performance support solution, businesses can achieve real-time visibility into employee skills. Enhanced visibility empowers management to make informed decisions about training, development, and resource allocation, ensuring that the right skills are available precisely when needed.

9. Inconsistent Training Methods Are Leading to Skills Gaps

When organizations use informal methods like shadowing for training, problems can arise. This can cause employees to have different skills and knowledge. As a result, some workers may perform better than others. Implementing standardized digital training programs through a worker performance support app can guarantee uniformity in training delivery. This guarantees that every employee is provided with identical information and assistance, which in turn enhances the overall skills of the staff and ensures effective onboarding of new hires.

10: Difficulties in Tracking Skills Development Are Stalling Employee Growth

Many workers find it challenging to track their skills development because records are kept on paper or in a corporate Learning Management System (LMS) that they cannot access. A good employee performance app can create a single system for tracking skill development. This helps staff see their growth and achievements as they happen.

This visibility empowers workers and enhances management's ability to identify skill gaps and areas for improvement. A sturdy framework for monitoring skill development not only promotes an environment of constant learning but also aids employees in their career advancement.

Conclusion: Embrace a Connected Worker Support App to Transform Your Factory

If any of these signs resonate with you, it’s evident that your organization is ready for a transformation. Investing in a powerful employee performance support application can fill the identified gaps, resulting in increased efficiency, minimized downtime and improved employee satisfaction.

Prominent manufacturers like Mars, Barry Callebaut, and Danone have acknowledged the necessity for efficient solutions to aid their factory employees. They have opted for Poka, an innovative worker performance support application that combines digital content, communications, and collaboration in a unified, worker-focused interface tailored to cater to the distinct requirements of the factory floor.

Poka allows workers to conveniently scan a QR code on their equipment or work orders with an iPad to get important information updates, work instructions, and training manuals. The app helps employees talk to each other. It lets them solve problems quickly. It tracks their growth and learning and has many other features. This capability not only empowers workers but also fosters a culture of collaboration and continuous improvement.

By digitally connecting and empowering their workforce through the adoption of Poka, manufacturers have experienced significant benefits, such as:

This forward-thinking approach helps organizations do well in smart manufacturing. It shows that investing in tools to support workers is not just a choice – it is necessary to stay competitive.

Check out our 2-minute video to hear how companies like Tyson Foods, Mars, and others have leveraged Poka to digitally transform their factory floors.

Read more on how your factory floor can evolve into a hub of innovation and collaboration.

Ready to empower your factory workers and transform productivity? Let us show you how Poka can bridge the gaps in your current system. Book a personalized demo today and experience firsthand how easy it is to keep your team connected, engaged, and equipped for success!

The Role of the Connected Worker in Total Productive Maintenance

This article was updated in November 2024 for accuracy.

Top 10 Signs You Need a Better Way to Support Your Factory Workers