How to Digitize Layered Process Audits with Connected Worker Technology

Learn how connected worker technology can help you standardize and digitize layered process audits for improved accuracy and better quality results.

Digitized Layered Process Audits (LPAs) are important in manufacturing for establishing and enhancing process standardization, quality management, multi-level workforce engagement, risk mitigation, and quality standards compliance. The primary function of a Layered Process Audit is to focus on observing and validating how products are made to ensure process and product quality. This effectively protects manufacturers and frontline manufacturing personnel from defects and process issues before they can do any damage.

digital layered process audits

Many crucial manufacturing processes are still carried out using outdated pen-and-paper methods; and as the industry continues to evolve, digitization is essential to remain competitive and maintain proper quality and safety standards. Layered Process Audits are no exception, with digitized layered process audits now a necessity, rather than a luxury, for organizations looking to keep pace, elevate their audit processes, and meet the demands of the evolving industry.

Learn more about how to streamline LPAs with connected worker technology, implement digital LPAs, and the benefits of AI-powered analytics for digitized LPAs and overall quality management excellence in manufacturing below.

Benefits of a Digitized Layered Process Audit

Connected worker platforms allow manufacturers to replace paper-based audit forms (like a layered process audit) with digital checklists that can be accessed and completed on mobile devices, allowing for:

  • Standardized audit formats and best practices across audit layers
  • Real-time data collection and improved audit tracking
  • Mobile access to information and knowledge including relevant documents, procedures, and historical data
  • Automated audit scheduling and notifications for consistent audit frequency across layers and reduced administrative burden
  • Real-time issue reporting and escalation for faster response and issue resolution
  • Improved data analytics and reporting to generate and apply insights as well as identify recurring issues and root causes
  • Overall system integrations with things like ERP, MES, and CMMS

These abilities offer a significant boost to manufacturers in terms of operational efficiency, risk mitigation, workforce development, and cost reduction.

Implementing Digital Layered Process Audits

Manufacturers can digitize LPAs and streamline their quality management processes through AI-powered connected worker technologies, improving data quality and driving faster, more effective quality improvements across the organization.

layered process audit framework

Implementing digital Layered Process Audits (LPAs) involves several steps, from selecting the right platform to engaging the team and ensuring proper integration with existing systems. Below is a step-by-step guide to implementing digital LPAs effectively:

1. Choose the right Digital LPA Platform

Research and select a digital LPA platform that meets your organization’s needs. Consider factors like:

  • Ease of use (especially for mobile devices)
  • Customizability (to fit your audit checklist and process requirements)
  • Integration with existing systems (e.g., ERP, quality management systems)
  • Reporting and analytics capabilities
  • Scalability for future needs

2. Develop and Digitize Audit Checklists

  • Standardize Audit Checklists: Create or review the audit checklists for each layer of the audit process. Ensure they are aligned with your goals, operational requirements, and industry standards (e.g., ISO, IATF).
  • Digitize the Checklists: Input these checklists into the digital platform. Ensure that they are tailored to different levels of the audit process, from shop floor employees to higher-level management.
  • Customize Alerts and Criteria: Set up criteria for success/failure and alerts for non-conformance. This can include conditional triggers where a failed audit automatically prompts corrective actions.

digitized layered process audit LPA with augmentir quality control checklist

3. Integrate with Other Systems

  • Link to Quality Management Systems (QMS): Integrate the LPA platform with your existing QMS, ERP, or other relevant systems to streamline data sharing and analysis.
  • Automate Corrective Action Processes: Ensure that non-conformance findings in the audit automatically trigger corrective action workflows, and link them to task management or follow-up procedures.

4. Monitor, Analyze, and Improve

  • Track Real-time Results: Use the platform’s dashboards and analytics features to monitor performance metrics, such as audit completion rates, non-conformance trends, and the time taken to close corrective actions.
  • Conduct Regular Reviews: Hold periodic review meetings with the audit team and management to discuss audit findings and trends. Use this information to drive continuous improvement in processes.
  • Make Adjustments: Based on the insights from the audits, adjust the audit checklists, procedures, and corrective action plans as needed.

5. Foster a Culture of Continuous Improvement

  • Encourage Engagement: Foster a culture where employees see the value in LPAs and actively participate in the process. Offer incentives or recognition for high levels of engagement or process improvements resulting from audits.
  • Regularly Update the System: Keep the digital platform and audit processes updated to reflect changes in standards, regulations, or internal processes.
  • Leverage Advanced Analytics: Over time, use advanced analytics and machine learning (if available) to predict potential non-conformance areas and further streamline corrective actions.

By following these steps, you can effectively implement a digital Layered Process Audit system that enhances visibility, accountability, and process control across your organization.

Driving Continuous Quality Improvement with Digitized LPAs

Excellence in quality management drives success in manufacturing. Digitizing and updating old processes with AI, connected worker platforms, and even simple digital layered process audit software allows manufacturing organizations to better identify and prevent defects at their source and protect against rework, customer complaints, costly product recalls, and reputational damage.

Recent innovations in AI technology and applications caused an explosion of growth all across the world and in various industries. Manufacturing is uniquely situated to adopt these technologies for massive growth. One valuable use case is the use of AI to optimize quality management, specifically to optimize audit processes like LPAs for drastically improved results and insights that simply weren’t possible previously.

AI analytics combined with connected worker technologies digitize and streamline layered process audits allowing manufacturers to capitalize on data capture for:

  • Trend analysis across different audit layers, departments, and locations
  • Automated population of audit forms with relevant data
  • Seamless creation of digital work instructions from audit findings
  • Application of cobots, generative AI assistants, or AI copilot technologies to support auditors and workers alike.

But this does not stop there, according to a study by McKinsey & Company, companies that prioritize quality management achieve higher levels of employee engagement. Engaged employees are more likely to be committed to producing high-quality products, resulting in increased productivity and customer satisfaction. The addition of AI to capitalize on connected worker data and feedback to generate insights, support enhanced decision-making, and create better processes offers manufacturers a path forward into the future with a better-equipped and supported frontline workforce.

Interested in learning more?

If you’d like to learn more about how Augmentir streamlines and optimizes quality management processes like digital layered process audits and more, schedule a demo with one of our produce experts.

 

See Augmentir in Action
Get in Touch for a Personalized Demo
Book A Demo

Four Ways Connected Worker Technology is Helping Frontline Workers Operate in Today’s New Normal

The impact of COVID-19 has placed pressure on manufacturing operations leaders to maintain business operations and business continuity. Here are four ways that connected worker technology is shaping the future industrial workforce.

Four Ways Digital Technology is Helping Frontline Workers Operate in Today’s New Normal

The global pandemic has changed frontline work and given workers a new type of normal – and for many manufacturers, the change will be permanent.

The impact of COVID-19, and subsequent changes in how factories are located, staffed, managed and digitized, as well as how customers are supported is placing pressure on manufacturing operations leaders. According to McKinsey & Co., manufacturing companies of every size are now turning to digital and connected worker technology as a way to maintain business operations and business continuity. Technologies such as artificial intelligence (AI) and augmented reality (AR) based remote collaboration are now central to the corporate innovation portfolio of any business leader and crucial to boosting productivity at a time when enterprises most need it.

Here are four ways that connected worker technology is shaping the future industrial workforce and helping frontline workers operate at peak levels of safety, quality, and productivity during these times.

1. Provide Remote Assistance

Travel limitations and restrictions have forced companies to re-think how they support their staff and customers. As a result of COVID-19, manufacturers have initiated policies that encourage remote working, eliminate non-essential travel and instruct employees who are sick or under quarantine to stay home. This directly impacts the progression of operations that typically take place when multiple workers collaborate onsite.

AR-based virtual collaboration tools are providing business continuity for companies that can no longer rely on face-to-face interactions.

With on-demand remote expert functionality, onsite workers can quickly pull in an offsite colleague when their expertise is required. Many manufacturers are also extending this out to support virtual collaboration with 3rd party dealers and suppliers, customers, and even field service teams for those companies that provide equipment service and support. Digital work procedures, videos, realtime data and more are readily available and allow remote subject matter experts to intelligently guide and help workers on the job.

2. Reimagine Training

One of the challenges that has emerged during this pandemic has been workforce variability. Flexible staffing is becoming more the norm, and training/re-skilling is more important now than ever.

Traditional methods of classroom training have now become impractical if not impossible, and many companies are looking towards connected worker technology to help shorten training times and accelerate onboarding for new technicians. Use augmented reality (AR), visual aids, and contextual information to guide workers through complex tasks and deliver AR-based training experiences.

For example, Bio-Chem Fluidics, a mid-sized manufacturing company, was able to reduce new employee training time by over 80% – from three months down to two weeks. The use of visual aids and short training videos within digitized work procedures allowed their operation to onboard technicians at a faster rate and reduce downtime during learning periods, resulting in improved productivity.

3. Improve Quality and Productivity through Augmented Work Instructions

Another area where connected worker technology helps is through augmented work instructions. Equipped with digital devices that could include tablets, mobile phones, or even AR-enabled industrial smart glasses, frontline workers are able to receive fully augmented, guided instructions on any device to improve productivity, quality and allow workers to perform their jobs more independently. These help guide workers with visual aids, AR/MR experiences, and contextual information.

Digital work instructions enable manufacturing workers, customers, dealers, and field service technicians to complete assembly, installation, maintenance, or repair procedures at 100% quality without requiring face-to-face support. Artificial intelligence and machine learning (AI/ML) can be used to amplify the value that digital work instructions bring to the connected worker. AI is used to personalize the instructions to each worker’s proficiency level, which helps intelligently close the skills gap and enable workers to perform at their best.

4. Uncover Continuous Improvement Opportunities

It’s critical for manufacturers to monitor processes and track progress during this time so that they can make quick adjustments to ensure overall optimization. Our view at Augmentir is that the purpose of a connected worker platform isn’t simply to deliver instructions and remote support to a frontline worker, but rather to optimize the performance of the connected worker ecosystem.

Incorporating AI into a connected worker strategy enables true organizational optimization using the rich stream of activity data to recommend improvement actions to frontline workers, continuous improvement specialists, trainers, manufacturing engineers, and operation and service managers.

  • AI-based connected worker platforms can use granular data to identify the largest opportunities across the frontline workforce
  • For example, Augmentir’s AI-powered connected worker platform looks through all job data and uses AI to cleanse the data set and recognize the largest improvement opportunities for your company in productivity, training, quality, and delivers them to your team automatically through insights in the system
  • In doing that, the system learns a lot about each worker, and can dynamically match the instructions to each worker’s proficiency and capability, intelligently closing the skills gap
  • Finally, AI bots allow you to accumulate tribal knowledge (that your subject matter experts know) and convert it into a scalable, digital corporate asset

With an ecosystem of content authors, frontline workers, subject matter experts, operations managers, continuous improvement engineers, and quality specialists, there are dozens of opportunities to improve performance.

Now is the time to consider these and start digitizing and connecting your frontline workforce. These technologies are proving to be practical and effective ways to close skill gaps and transform training efforts – allowing your frontline workers to work safely and efficiently in today’s new normal. Book a personalized demo to learn more.

 

Duracell Joins Augmentir’s Customer Advisory Board

,

Duracell, the world’s #1 consumer battery manufacturer, is now part of Augmentir’s Customer Advisory Board, joining Colgate-Palmolive, Sargento, Graphic Packaging, and Hunter Industries.

When it comes to high-performance batteries, there’s one brand that everyone knows and loves – Duracell.

We are excited to announce that the world’s #1 consumer battery manufacturer is now part of Augmentir’s Customer Advisory Board. Duracell’s collaboration and expertise are a major leap forward in our mission to transform industrial work and empower frontline workers worldwide with AI-driven connected worker solutions.

augmentir welcomes duracell to customer advisory board

Duracell’s commitment to innovation and excellence aligns perfectly with our vision of leveraging connected worker and AI technology to augment and transform the industrial workforce. With Duracell on board, we are set to supercharge our innovation and advance our impact on the connected worker market and manufacturing arena.

Our Customer Advisory Board was announced last September and consists of leading manufacturers from a wide range of industries who understand the importance of today’s unique industrial workforce challenges. Duracell joins other leading manufacturers including:

  • Colgate-Palmolive
  • Graphic Packaging International, LLC
  • Hitachi Energy
  • Hunter Industries
  • Sargento

This powerhouse lineup underscores our commitment to addressing the evolving needs of the industrial workforce. With Duracell and our other board members actively helping guide and shape the development of our AI-powered connected worker platform, we’re making sure it meets the industry’s needs head-on.

Collaborating for AI-Driven Connected Worker Innovation

Our AI-driven connected worker platform stands out by providing frontline workers with unparalleled personalized, real-time assistance and insights – enhancing productivity, skills management, workforce development, and operational efficiency. Unlike other platforms, ours was purpose-built to leverage advanced AI to continuously learn and adapt to each worker’s unique needs, offering tailored support and proactive guidance.

Recently, we were named the market-leading solution in the connected frontline workforce application space by LNS Research, highlighting us as the industry’s Most Complete Product. Augmentir was also named 2023’s “Connected Worker Company of the Year” by Frost & Sullivan, as well as named a “Cool Vendor” for Manufacturing Operations by Gartner.

“We are honored to welcome Duracell to our Customer Advisory Board,” said Russ Fadel, CEO of Augmentir. “Their expertise and forward-thinking approach will provide invaluable insights, helping us to continue delivering cutting-edge solutions that drive operational efficiency and workforce productivity.”

Duracell’s participation on the board involves sharing industry best practices gained from their extensive experience in manufacturing and supply chain management. They will provide critical feedback on new features and enhancements, ensuring that our AI-powered platform meets the practical needs of the industrial workforce. Additionally, Duracell will collaborate with us and other board members to develop innovative strategies to address common challenges in the industrial sector, such as improving safety, increasing productivity, and reducing downtime.

This partnership underscores our shared dedication to empowering the workforce of the future by harnessing the power of advanced technologies. With the input of our customer advisory board, we aim to create more intuitive, effective, and user-friendly solutions that help companies optimize their operations and support frontline workers to achieve next-level performance. Together, we are confident that we can drive meaningful change and set new standards for excellence in the industrial world.

Interested in learning more?

If you’d like to learn more about how Augmentir and our AI-powered connected worker solution is transforming industrial frontline work, schedule a demo with one of our product experts.

 

See Augmentir in Action
Get in Touch for a Personalized Demo
Book A Demo

Augmentir: New Look, Same Powerful AI and Connected Worker Solution

You may have noticed that our website and brand look a little different. Augmentir has a new look, but under the hood, its the same powerful AI that is helping to transform the industrial workforce of the future.

You may have noticed that our website and brand look a little different. Well, that’s because behind the scenes for the past few months, we’ve been under construction (no pun intended).

Augmentir was founded in 2018 with the vision to use AI to empower the industrial frontline workforce to perform at their best. This was a continuation of our rich history – our founding team has been at the forefront of three of the most important of these software technology revolutions in manufacturing over the past three decades – Wonderware Software in 1987, Lighthammer in 1997, and ThingWorx in 2008.

A lot has changed since then. The world we live in today is not the same as it was 4 years ago. And in the last two years, the COVID-19 pandemic has altered the stability of the workforce and drastically magnified some of the industry’s top workforce challenges, which stem from the unprecedented levels of dynamism in the areas of skills diversity, reduced tenure, and increased churn from the “Great Resignation”. Unlike the stable and predictable workforce of the recent past, today companies have to live in the new normal where workers are hard to find, hard to engage, and hard to keep.

These top challenges of today have only reinforced the need for an AI-powered, data-driven approach to empowering frontline workers.

This data-driven era we’re entering into is one of continuous learning and development with tools like remote collaboration and digitized work processes truly integrating frontline workers into the fabric of the business from a collaboration standpoint whereas they may have been overlooked before.

Augmentir’s AI-powered connected worker platform provides the tools to not only survive in this new normal but to thrive.

You can’t build a truly modern, connected workforce without AI

The term “connected worker” has become a recent buzzword in the manufacturing world, and is now considered a tool that the new generation of workers expect to work with. But true connected work means using AI to allow frontline workers to have access to internal and external resources that are appropriate for when and how they need them.

Augmentir isn’t your typical connected worker platform. Our platform was built from the ground up on an AI foundation. AI algorithms are ideal for analyzing large amounts of data collected from a connected workforce. AI can detect patterns, find outliers, cleanse data and find correlations and patterns that can be used to identify opportunities for improvement and create a data-driven environment that supports continuous learning and performance support. Our connected worker platform utilizes AI to help train, guide, and support today’s frontline workers in a dynamic workforce by combining digital work instructions, remote collaboration, continuous development and advanced on-the-job training capabilities.

This approach aligns perfectly with the dynamic, changing nature of today’s workforce, and is ideally suited to achieve and sustain effective on-the-job performance.

As the world’s only AI-powered connected worker platform, we decided it was time to refresh our brand identity to accentuate our strongest feature and the thing that makes Augmentir unique – AI. We’re still the same AI-first connected worker platform that you know – just with a new look.

Empowering Your Frontline Workers to go the Extra Mile with Augmentir

Augmentir, a data-driven, AI-powered Connected Worker solution ensures that your frontline workers can go the extra mile every day by providing training, guidance, and support through the combination of digital work instructions, remote collaboration, and advanced on-the-job training.

In 2009, the Extra Mile America Foundation, a foundation promoting action and empowering positive change, first celebrated the “Extra Mile Day”.  Fast forward to 2014 and 527 US cities declared November 1st as the official “Extra Mile Day”. This day is designated to living life to your full potential, having a positive influence, and always striving to make the world a better place. At Augmentir, we believe in positive change, living to your full potential, and going the extra mile every day. In 2018, our founders decided to continue their journey of creating some of the most important software technology revolutions in manufacturing (Wonderware (1987), Lighthammer (1997), and ThingWorx (2008) by focusing on the most important asset, the frontline workers.

We recognize that today’s industrial workforce is different, and the old way of supporting workers just doesn’t work anymore. The static “one size fits all” approach used in the past, no longer applies to this generation of workers.

Augmentir, is a data-driven, AI-powered Connected Worker solution that ensures that frontline workers can go the extra mile every day by providing training, guidance, and support through the combination of digital work instructions, remote collaboration, and advanced on-the-job training.  

As your workers become more connected, companies have access to a new rich source of activity, execution, and tribal data, and with proper AI tools they can gain real-time insights into areas where the largest improvement opportunities exist. Artificial Intelligence lays a data-driven foundation for continuous improvement in the areas of performance support, training, and workforce development, setting the stage to address the needs of today’s constantly changing workforce.

When it comes to our frontline workers, let’s enable them to go the extra mile, not just on November 1st, but every day, by empowering them with the only AI-powered Connected Worker solution.

Performance Management in Manufacturing: Best Practices and Examples

Learn about performance management in manufacturing, best practices and implementation methods, and key examples and use cases.

Manufacturing performance management is the process of setting, monitoring, and optimizing key performance indicators (KPIs) related to workforce performance and production processes in manufacturing environments. It includes real-time monitoring and evaluation of employees’ work, as well as the continuous improvement of operational workflows to ensure optimal efficiency, product quality, and adherence to both safety requirements and organizational goals.

performance management in manufacturing best practices

Through data-driven insights, performance management software, and regular assessments, performance management aims to enhance employee productivity and engagement, reduce downtime, and maintain a competitive edge in the industry. Read our blog post below to learn more about performance management in manufacturing including:

5 Best Practices for Performance Management in Manufacturing

To get the best value from your performance management system here are five best practices for performance management in manufacturing:

1. Clear Goal Alignment:

Organizations must ensure that performance management processes align with overall organizational goals. They must clearly communicate objectives to employees at all levels, linking individual and team performance metrics to broader manufacturing and business objectives. This fosters a sense of purpose in frontline teams, engages workers, and helps employees understand how their efforts contribute to the company’s success.

2. Real-time Monitoring and Data Analytics:

Implement real-time monitoring of production and shop floor processes and equipment performance through the use of AI and connected worker technology. Utilize data analytics and AI-driven processing to gain insights into worker performance trends, identify bottlenecks, and facilitate data-driven decision-making. The ability to monitor operations in real-time not only enables proactive interventions to maintain efficiency, it also ensures fairness, accuracy, and transparency in performance measurement.

Pro Tip

Truly optimized performance management is only possible when the work being done is connected to worker skills and competency training. The best way to do this is with AI-powered connected worker technology that uses AI to deliver insights on workforce development and act on data collected from connected frontline workers.

A

3. Employee Training and Development Programs:

Prioritize ongoing training and development programs for manufacturing personnel. Equip frontline workers with the necessary skills to adapt to evolving technologies and operational requirements. Use performance management systems and other digital tools like skills matrixes to identify skill gaps, set training goals, and track progress, ensuring a skilled and adaptable workforce.

4. Regular Performance Reviews and Feedback:

Conduct regular performance reviews that provide constructive and timely feedback to employees. Use these reviews as opportunities to recognize achievements, address areas for improvement, and set new performance goals. Foster open communication between managers and employees to encourage continuous improvement.

5. Integration with Continuous Improvement Initiatives:

Integrate performance management systems with “kaizen” or continuous improvement initiatives such as Lean or Six Sigma. Use data from performance metrics to identify opportunities for process optimization, waste reduction, and efficiency improvements. This ensures that performance management is not only evaluative but actively contributes to the ongoing enhancement of manufacturing processes.

Leveraging these best practices contributes to a holistic performance management process that aligns manufacturing organizations and their frontline workforce with strategic goals, optimizes operations, and creates a culture of continuous improvement.

Key Performance Management Strategies for Manufacturing Leaders

The following are a few examples of performance management strategies that manufacturing leaders, plant managers, and shift supervisors should consider when implementing their performance management process.

Line-shift Goals

Manufacturers often use production planning and scheduling systems to manage line shifts effectively and ensure a smooth transition between different production configurations. While line shifts in manufacturing are often necessary for adapting to changing demands, introducing new products, or optimizing efficiency, they can also pose challenges, including downtime, quality control issues, employee fatigue, and planning issues. By establishing clear and measurable objectives for each line shift or individual worker that aligns with organizational goals, production leaders can ensure production goals are met.

Individual Meetings and Communication

Manufacturing leaders should implement a performance management strategy that incorporates 1-1 meetings and communication. Regularly providing constructive feedback to employees on their performance can improve performance and boost employee engagement. Offering coaching and development opportunities to enhance skills and capabilities.

Continuous Training

Continuous training in manufacturing involves enabling workers to learn new skills regularly. It’s a great way to improve employee performance and innovation, as well as engage and retain top talent. A good example of a continuous learning model is everboarding, a modern approach toward employee onboarding and training that shifts away from the traditional “one-and-done” onboarding model and recognizes learning as an ongoing process.

Performance Management Tools

Implementing performance management tools can help automate ongoing employee evaluation, as well as align employee performance with other key manufacturing KPIs, including production quality, machine uptime, and labor utilization. These tools can also be used to identify continuous improvement opportunities. This allows manufacturing leaders to adapt and refine approaches based on feedback and outcomes.

Simplifying Performance Management with Digital Tools

According to Forbes, as the future of work evolves and changes so must performance management, traditional methods may no longer be as successful in an era where the workforce is constantly changing.

Digital tools such as connected worker solutions and AI-driven analytics help simplify performance management systems by streamlining processes, improving efficiency, and providing more accurate insights. Implementing these connected worker solutions automates the collection of performance-related data from various sources including connected frontline workers, IoT devices, software systems, and more. This eliminates the need for manual data entry, reducing errors and ensuring real-time access to up-to-date information.

By digitizing the performance management process, organizations create a centralized platform for storing and managing performance-related data. This centralized knowledge base makes it easy for managers and employees to access relevant information, track progress, and collaborate on performance goals. Furthermore, AI-driven connected worker solutions allow for digital performance tracking, customized training and skills development planning, workflow optimization, and improved predictive maintenance.

performance management best practices in manufacturing

Through these digital tools and technology, manufacturing companies can simplify performance management processes, improve operational efficiency, and adapt to the demands of a rapidly evolving industry while fostering a culture of continuous improvement and development for their manufacturing workforce.

Augmentir is the world’s leading connected worker solution, combining smart connected worker and AI technologies to drive continuous improvement and enhance performance management initiatives in manufacturing.

Augmentir is trusted by manufacturing leaders as a digital transformation partner improving training and development, workforce allocation, and operational excellence through our AI-driven True Productivity™ and True Performance™ offerings, as well as digitizing and optimizing complex workflows, skills tracking, and more through our patented smart, connected worker suite. Schedule a live demo today to learn more.

 

See Augmentir in Action
Get in Touch for a Personalized Demo
Book A Demo

How Digital Standard Work Promotes Operational Excellence in Manufacturing

Learn how Digital Standard Work effectively transforms manufacturing production and enables operational excellence.

Manufacturing organizations are feeling the pressure of increased customer demands, skilled labor shortages, and intense shifts in their frontline workforces, however, they can effectively overcome these obstacles with digital standard work enabled by smart connected worker technology. Digital standard work promotes operational excellence in manufacturing through facilitated knowledge-sharing, enhanced process standardization, increased employee engagement, improved workforce agility, and overall optimization of workforce abilities.

digital standard work in manufacturing

Standardized work in manufacturing (centerlining, machine setup/maintenance, inspection checklists, workforce training, lubrication procedures, etc.) is effective for continuously improving the most efficient and safe methods for performing work to meet customer demand while minimizing waste. Digital Standard Work takes these processes one step further, enhancing them with digital technology to establish a true culture of continuous improvement where frontline workers and shop floor processes benefit from digital workflows, collaboration, AI-powered guidance, generative AI assistants, real-time access to centralized knowledge bases, and more.

By redefining standard work for the digital age, manufacturers can achieve operational excellence through increased efficiency, quality, flexibility, and innovation across their frontline workforces. Read more on Digital Standard Work and how it effectively transforms manufacturing production and enables success:

Digitizing Standard Work in Manufacturing

According to Forbes and McKinsey, through digital tools manufacturers can reduce machine downtime by 30% to 50% and quality-related costs can be reduced by 10% to 20%. Effectively digitizing manufacturing standard work through smart, AI-driven connected worker technology involves:

  • Interactive Digital Work Instructions
    Replace paper-based standard operating procedures (SOPs) with interactive digital work instructions that include multimedia elements like videos, images, and animations. These can be accessed by workers on tablets, wearables, and other mobile devices right on the shop floor.
  • Data Capture and Integration
    Leverage smart tools and sensors to automatically capture data from the manufacturing process, such as torque values, cycle times, and quality checks. This data can be integrated into the digital work instructions to provide real-time feedback and ensure adherence to standards.
  • Workflow Automation
    Automate non-value-added tasks like data entry, approvals, and documentation through connected worker platforms. This streamlines workflows, reduces errors, and frees workers to focus on value-adding activities aligned with standard work.
  • Knowledge Management
    Digitize and centralize tribal knowledge, best practices, and process documentation in a connected worker platform. This ensures standardized methods are easily accessible and updatable for consistent knowledge sharing across the workforce.

Using smart, connected worker platforms to digitize and optimize standard work in manufacturing drives improved productivity, ensures better and more consistent product quality, and fosters a safer work environment for enhanced operational success.

Pro Tip

Using a low-code no-code workflow builder simplifies the creation of complex digital workflows for frontline work processes. Furthermore, integrating remote collaboration tools facilitates real-time guidance, knowledge sharing, and the ability to update standard work procedures based on captured tribal knowledge.

A

Engaging Frontline Workers with Digital Standard Work

As manufacturing workforces shift due to retirement and tribal knowledge loss, effective workforce training has become critical for continued success. Interactive digital interfaces, augmented and enhanced capabilities, and wearable technologies make standard work practices like workforce training more engaging and accessible, improving workforce adoption and adherence.

Digital tools facilitate information visibility and knowledge sharing among frontline workers, enabling them to learn from each other, share best practices, and contribute to a culture of continuous improvement. By tracking and analyzing performance data from digital systems, manufacturers can identify top performers, provide personalized feedback, and recognize achievements, fostering a sense of engagement and motivation among frontline workers.

Digital Standard Work empowers frontline workers by involving them in process improvements, recognizing their contributions, and providing opportunities for learning and growth, leading to increased job satisfaction and commitment. By leveraging digital technologies and interactive interfaces, manufacturers can transform Standard Work procedures into engaging and empowering experiences for their frontline workforce, driving productivity, quality, and a culture of continuous improvement.

Most importantly it gives manufacturing frontline and factory staff the tools they need to be successful and thus create a more satisfied environment where employees come to work and feel good about what they are doing and how they are doing it.

Driving More Effective Collaboration

Digital standard work also facilitates better collaboration across your frontline teams. Effective communication starts with digital tools, and by implementing digital standard work with connected worker technology, manufacturers can connect frontline team members across shifts, departments, locations, and languages, improving visibility into workforce planning, training, skills tracking, daily management, troubleshooting, and more.

industrial collaboration with augmentir

From frontline workers to executives, a digital standard work strategy that leverages connected worker technology allows employees to collaborate seamlessly and easily access information. Connected worker solutions that include industrial collaboration tools allow workers to virtually connect to subject matter experts for remote guidance and assistance. These software tools are becoming commonplace in manufacturing and other industrial settings, where companies are faced with an increasingly distributed and remote workforce, yet still require team collaboration to help troubleshoot and resolve issues. In a nutshell, workers can get more done with greater accuracy in less time.

Interested in learning more?

If you’d like to learn more about how Augmentir and our AI-powered connected worker solution digitizes standard work, streamlines operations, improves communication, and empowers frontline workers with the tools and information they need, schedule a demo with one of our product experts.

 

See Augmentir in Action
Get in Touch for a Personalized Demo
Book A Demo

The Difference Between Skills Development and Training in Manufacturing

Learn the difference between skills development and training in manufacturing, how they are important, and how the management of them can be improved through continuous learning methodologies and emerging technology.

At first glance, training and skills development seem synonymous and are often used interchangeably, but they have different purposes and goals. However, despite these differences, both are equally important for every organization, especially in the case of the manufacturing industry. According to Training Magazine, 57% of manufacturing organizations reported training and workforce development budget increases to address the widening skills gap and the skilled labor shortage.

the difference between skills development and training in manufacturing

At the most basic level, training is the process companies use to build the skills of new employees so they’re well-equipped to perform the role that they were hired for. While skills development, on the other hand, includes ongoing education, mentoring, and professional experiences that help employees grow into future roles and opportunities.

Both are extremely valuable to overall organizational growth and success, however, it’s important to apply them at the right time and in the right way. Read more on both skills development and training in manufacturing, why they are important, and how they can be improved and enhanced through the proper application of learning technology:

What is Skills Development in Manufacturing

Skills development goes beyond training by aiming to enhance a broader set of competencies and capabilities. It focuses on building a more well-rounded and adaptable workforce encompassing not only the acquisition of specific skills, but also the improvement of problem-solving abilities, critical thinking, creativity, adaptability, and continuous learning.

Skills development in manufacturing refers to the process of enhancing the knowledge, abilities, and competencies of individuals involved in the manufacturing process. It involves providing training and education to workers, engineers, and technicians to improve their technical, operational, and problem-solving skills. By providing training and development opportunities, manufacturing organizations can ensure that their workforce possesses the necessary skills and knowledge to perform their jobs effectively and efficiently.

Skills Matrix Template
Free Template
Start tracking worker skills, certifications, development progress, and capacity planning with our free Excel Skills Matrix Template. Download our template to get started, and learn more about tracking and manage your employee skills digitally with Augmentir.
Download Free Template

 

Many manufacturing industries face a shortage of skilled workers. Skills development programs help bridge the gap by training existing employees or new hires in the required competencies.

Overall, skills development in manufacturing is crucial for maintaining competitiveness in a rapidly changing industry. It ensures that the workforce remains adaptable, skilled, and capable of meeting the evolving demands of modern manufacturing processes.

Pro Tip

Implementing skills management software programs allow manufacturing organizations to digitize and effectively track worker skills, development progress, and intelligently assign work based on skills competencies, improving work allocation and workforce utilization.

A

What is Training in Manufacturing

Training in manufacturing primarily focuses on imparting specific knowledge, skills, or information to individuals. It often involves structured and organized programs designed to teach employees how to perform specific tasks or operate machinery and equipment. Training is often of shorter duration and may be task-specific or role-specific. It is designed to quickly bring employees up to a certain proficiency level in their current job.

The specific type of training required in manufacturing depends on the roles and responsibilities of the individuals involved, the company’s processes, and the industry in which they operate. Training in manufacturing is essential for several reasons:

  • Safety: Manufacturing processes often involve machinery, equipment, and materials that can be hazardous. Proper training ensures that employees understand and follow safety protocols, reducing the risk of accidents and injuries.
  • Quality Control: Quality in manufacturing is a critical, essential factor. Training programs teach employees how to maintain consistent product quality through accurate measurements, inspections, and adherence to quality standards.
  • Operational Efficiency: Training helps employees become more efficient in their tasks, reducing downtime, minimizing waste, and optimizing manufacturing processes.
  • Technology: Manufacturing is becoming increasingly technology-driven. Training equips employees with the skills to operate and maintain advanced machinery and systems.
  • Productivity: Engaged workers tend to be more productive, contributing to increased output and profitability for the manufacturing company.
  • Compliance: Manufacturing is subject to various regulations and industry standards. Training ensures that employees understand and comply with these requirements, avoiding legal and regulatory issues.

Effective training programs are designed to align with the organization’s goals and objectives, ensuring that the workforce is well-prepared and capable of contributing to the success of the manufacturing operations.

In summary, training in manufacturing is a subset of skills development, with a narrower and more specific focus on teaching job-related skills and knowledge. Skills development, on the other hand, is a more comprehensive and ongoing process that aims to develop a well-rounded and adaptable workforce capable of meeting the evolving challenges of the manufacturing industry. Both training and skills development are important for the success of a manufacturing organization, and they often complement each other in the development of a skilled and competent workforce.

How Can Technology Improve Manufacturing Skills Development and Training

Technology can significantly enhance manufacturing skills development and training by making the process more efficient, effective, and accessible. Incorporating these technological advancements into manufacturing skills development and training can lead to a more skilled and adaptable workforce, increased safety, reduced training costs, and improved overall manufacturing efficiency.

For example, technology enables experts to remotely assist and guide trainees through complex tasks. Workers can wear smart glasses or use mobile devices to share live video streams and receive real-time instructions. AI-driven connected worker solutions can assist in creating personalized learning paths for trainees based on the work they do, their progress, and their learning style.

Smart connected worker platforms, Learning Management Systems (LMS), and mobile apps can provide access to a wide range of training materials, including video tutorials, interactive modules, and assessments. These platforms allow workers to learn at their own pace and on their schedule, reducing the need for expensive and time-consuming in-person training.

Augmentir is the world’s leading, smart, connected worker solution using the foundational AI technologies underpinning ChatGPT to enhance manufacturing training, onboarding, and skills development. Leading manufacturing organizations are using our smart, connected worker suit and AI-driven insights to foster environments of continuous learning, and make skills development and training processes more personalized, accessible, and effective.

Schedule a live demo to learn why manufacturing leaders are choosing us to improve the training lifecycle with digital skills management tools, real-time insights, and more.

 

See Augmentir in Action
Get in Touch for a Personalized Demo
Book A Demo