Why Manufacturing Data Collection is Important and How to Improve It

Learn how manufacturing data collection can boost your bottom line and how to improve your gathering data techniques.

As manufacturing operations continue to modernize and evolve it is clear that without big data they won’t be able to sustain themselves. More and more manufacturers are looking to the tremendous capabilities and insights that digitized information can provide.

Shop floor data collection enables businesses to better measure, standardize, and optimize their production processes. It’s more important than ever before to have information that provides real-time insights for measurable progress.

Accurate reporting is more sustainable if management deploys a work culture and production infrastructure that supports digitized manufacturing data collection with connected worker platforms and solutions.

We discuss more about collecting data and how to improve it in the following sections:

manufacturing data collection

Examples of data collection in manufacturing

Data collection has many uses in a variety of situations for a wide array of manufacturing roles, from operators and engineers to plant managers and even leadership.

For example:

  • Plant managers use production dashboards to better gauge where operators need support, such as when a piece of equipment isn’t working.
  • Operators use machine interfaces that show the status of machine processes, part counts, and other measurable data to ensure they are meeting production targets.
  • Quality managers use production line data to identify and proactively address quality issues.
  • Engineers use collected data to check for any bottlenecks and adjust processes if necessary.
Pro Tip

Frontline workers often witness safety, quality, or maintenance issues on the factory floor. They are effectively a “human sensor” on the manufacturing process and can readily identify issues that need to be addressed. Today, recording data and resolving those issues is most often a manual and paper-based process. As such, there is minimal data collection, latency in resolving the issue, and little-to-no feedback to the frontline worker on resolution.

Equipping workers with mobile and digital tools can help optimize shop floor data collection.

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Which data to keep an eye on

Data generated on the shop floor can vary depending on the nature of work, the type of devices and technologies used, and the area of operation. Much of this data is of use to manufacturers and can be used to improve production processes.

Useful types of data for manufacturers that we recommend keeping an eye on are:

Inventory data: This type of data helps manufacturers keep track of product inventory. With it they can better gauge what items need to be restocked or which ones aren’t bringing any value to the customer as well as improve forecasting ability and more.

Quality and Inspection data: Ensuring product quality is a priority in manufacturing. Collecting data related to quality control, product inspection, and identifying defects or deviations from the desired standards is crucial to maintaining high-quality products and operations.

Machine data: Optimizing a production process can become difficult if you don’t know the status of your equipment. Manufacturing data collection can be digitized to analyze machine quality and performance, equipment runtime and downtimes, or other machine-related problems. Sensors monitor machine use and downtime, maintenance time, cycle time, and more. Studying this collected data helps identify where production can be improved to optimize efficiency.

Using AI, manufacturers can filter out the “white noise” data (or data that is of no use) to derive actionable insights more effectively than with traditional methods. Automating, standardizing, and digitizing manufacturing processes also improves manufacturing data collection procedures, making them streamlined, accurate, and reliable.

How to improve production data collection

Manufacturing data collection is transforming the way businesses handle their operational decisions. However, it can also pose setbacks to your production line if you gather inaccurate data.

Manufacturers must implement data collection systems that are easy to understand and navigate. You’re risking inconsistent data collection and reporting when you install a system with complicated functions and navigation tools. This can be avoided by focusing on people-centric, intuitive, and user-friendly systems that fit into the everyday flow of work for the frontline workforce.

quality manufacturing data collection

Implementing a unified system alone won’t improve data collection. Solutions that incorporate enhanced mobile capabilities and provide a truly connected enterprise are able to facilitate and optimize data collection efforts.

Examples of some useful smart, connected solutions to improve manufacturing data collection are:

  • Personalized, Digital Work Instructions: these intelligently deliver personalized digital work instructions matched to the needs of each worker in order to deftly guide them through and streamline day-to-day operations.
  • Connected Asset Management: these tools help simplify operations and maintenance of facilities, manage work and maintenance procedures, collaboration, and more.
  • Skills Management: these systems create visibility into workforce capability and optimize training programs, track individual and team progress, and initiate more targeted training and upskilling.

In addition to all the benefits listed above, these smart, connected worker tools are able to empower frontline workers with improved data-driven decision-making abilities that aid in safety, quality, and productivity efforts.

Benefits of digitizing shop floor data collection

Production data collection can make all the difference to a company’s success and give them a competitive edge. Smart, connected worker solutions enhance collection processes, allowing for real-time data collection, streamlined communication and collaboration between frontline workers.

Data-driven strategies can help with:

  • Creating better maintenance procedures based on real-time insights and equipment conditions
  • Optimizing worker productivity by minimizing production errors
  • Reducing downtime by providing real-time feedback
  • Developing higher quality products that increase customer satisfaction
  • Cutting supply chain costs due to better forecasting and waste reduction techniques

Implementing accurate, connected worker solutions can take your data collection efforts to the next level. That’s where Augmentir can help. We are the world’s only AI-driven, people-centric smart connected worker solution to standardize and optimize data collection using groundbreaking AI analytics technology.

See how our AI-focused connected worker solutions are driving results and improving data collection and data-driven decision-making across manufacturing operations – schedule a demo now.

 

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How to Improve Production Quality in Manufacturing

It’s vital that customers receive products that are free of defects. Learn 5 steps for improving production quality and how the right software can help.

Unexpected product quality issues can be a hassle to manage, especially when staff is stuck with processing time-consuming complaints, replacements, and refunds. Even worse, the impact on your bottom line can be substantial.

Manufacturers risk a significant cut to their profit margins when quality standards are not followed during the production process. To improve quality on the shop floor, plant managers need to pinpoint the root cause of quality issues.

Explore this article to learn how to start boosting your industrial processes today:

improve production quality in manufacturing

 

What is Production Quality

Production quality, or manufacturing quality, measures how well a manufacturing process develops products to fit design specifications. Manufacturers must devise a plan for how they want specific items to appear and function before creating them. This can include things like colors, durability, range of motion, measurements, and more. How well a product is made will depend on meeting these conditions.

After the design is planned, a number of factors can affect production quality, including:

  • Equipment/machines
  • Materials
  • Batch size
  • Human mistakes
  • Environmental issues
Pro Tip

Frontline workers often witness quality issues on the factory floor. They are effectively a “human sensor” in the manufacturing process and can readily identify issues that need to be addressed. Today, recording data and resolving those quality issues is most often a manual and paper-based process. As such, there is minimal data collection, latency in resolving the issue, and little-to-no feedback to the frontline worker on resolution.

Equipping workers with mobile and digital tools can help optimize production quality.

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5 steps to improve production quality

Although there may not be one single method for improving manufacturing quality, there are steps you can take to maximize success.

Here are five steps that should be part of your strategy.

Step 1: Assess your current workflow.

Start by reviewing your existing manufacturing processes. We encourage management to ask the following questions as part of their review:

  • What quality benchmarks do you hope to achieve for each product?
  • How much money have you lost from material, energy waste, and wasted time due to quality problems?
  • What is your margin for improvement?
  • What quality standards are implemented in the creation of products?
  • Is your equipment inter-connected with different databases, or just a single database?

We recommend connecting your factory devices to one central database with a cloud-based, connected worker solution that operations management can use to create, assign, manage, and monitor the work being done. This kind of software can help streamline operational processes and track results in real-time.

Step 2: Remove unneeded processes.

Once you’ve accessed your current workflow and set up a connected worker solution to collect frontline worker data, we recommend coupling it with AI-powered analytics that can derive actionable insights. Then you can use these actionable, data-led insights to see which processes are adding value and which ones are not.

quality manufacturing data collection

Step 3: Boost worker training.

It’s important to maintain regular employee training and skills development programs to ensure workers are staying on top of industry best practices, equipment upkeep, and product knowledge. AI-powered connected worker solutions make learning more accessible, engaging, and effective.

Step 4: Create quality goals.

Developing quality goals is a great way to measure product benchmarks, production time, material usage, labor cost, working hours, and more. By digitizing and standardizing quality processes, you’ll be able to see which manufacturing processes are adding to your bottom line and which can be eliminated to bring value to the customer.

Step 5: Cut production waste.

Cutting waste from your production run can improve your business’s supply chain management. Connected worker solutions can identify which processes aren’t needed to reduce waste. It also gives real-time visibility into your supply chain to help you manage supply problems, optimize manufacturing processes, and adjust production schedules.

FAQs about improving production quality

How can the quality of the manufacturing industry be improved?

Measuring your current production processes to see which methods work can help improve product quality and increase the value of goods manufacturers make. You can strengthen the processes related to production by digitizing and automating them. Implementing a connected worker solution that offers real-time insights helps ensure that all goods meet quality standards and compliance criteria.

How do you ensure product quality in manufacturing?

There are a number of factors that can ensure product quality in manufacturing. We recommend following the five steps listed above to minimize defects as well as improve workflow and output.

What are 5 ways to improve production quality?

Assessing your current workflow, eliminating needless production processes, boosting work training, creating quality goals, and cutting production waste can all help improve production quality (see list above for a full description of each, as well as how implementing a connected worker solution can boost their overall impact).

Why is quality improvement important in manufacturing?

Enhancing production quality in manufacturing is a must as the industry moves towards fully connected enterprises, digital transformation, and automation. Businesses risk huge profit losses when quality standards are neglected in the creation of each product.

Digitize and Improve Production Quality with Augmentir

By digitizing and standardizing quality protocols, organizations can maintain compliance through an auditable and verifiable quality management system that gives workers access to the correct procedures as they need them with expert guidance. This ensures that tasks are performed in a standard manner to avoid errors on the production floor, reduce defects, and decrease resources lost to rework.

Refining your manufacturing methods can be difficult without the right technology. Augmentir’s AI-based connected worker solution makes streamlining and optimizing your production and quality procedures easier than ever before. Get in touch for a live demo today and learn why manufacturers are choosing Augmentir to help standardize and digitize quality processes!

 

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Benefits of Manufacturing SOPs and How to Write Them

Learn how to write manufacturing SOPs and the benefits of having standard operating procedures in a manufacturing operation.

Standard operating procedures, or SOPs, will change the way you run your manufacturing operations.

SOPs are imperative to a properly organized management structure. They are step-by-step guidelines workers must follow when carrying out tasks to standardize work and are designed to meet industry regulations.

Essentially, they provide general info about assignments, including the tools, methods, or machinery needed to complete projects. SOPs indicate what the task is, who will perform it, how it should be completed, and when it should be completed.

manufacturing sop

For example, manufacturers may write SOPs for employee training to reduce risk and injury. Leadership may also use procedures to assign goals and measure employee performance.

Read on to find out more about the benefits of manufacturing SOPs and how to write them by exploring the following topics:

Advantages of Implementing Standard Operating Procedures

According to Forbes, a comprehensive SOP keeps workers on the same page and improves efficiency and accuracy. Without documented procedures, there is no way to set proper standardized processes and workers might try to complete jobs in non-standard methods, which leads to disruptions in the production processes and causes all sorts of quality issues in a manufacturing environment. Thankfully, SOPs work to prevent that from happening.

Some of the advantages of using SOPs include:

  • Meets regulatory compliance: Product inspectors constantly ask to review SOPs when conducting audits. These serve as the point of reference for whether specific measures followed meet industry guidelines.
  • Standardizes tasks: The point of written procedures is to establish a standard way of completing tasks. They enable tasks to be performed in the same way across the company.
  • Improves accountability and tracking: SOPs define who is responsible for a work order, maintenance check or inspection. This reporting can improve accountability across departments. If a task wasn’t completed accordingly or a procedure was missed, management can take necessary steps to prevent it from happening again.
Pro Tip

Digitized SOPs can further improve tracking and traceability features, helping manufacturers comply with regulations and quality standards. With digital SOPs it becomes easier to maintain records of every step in the production process, including who performed each task and when.

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How to write a manufacturing SOP

Writing a comprehensive set of SOPs can help workers perform tasks in the safest and most efficient way possible. Although there isn’t an official way to write procedures, you can follow certain steps to make them more effective:

Step 1: Establish a goal.

It’s important to think about what you want your SOP to accomplish. Regardless if you’re starting a new process or improving an existing one, figuring out the end goal will make it easier to complete the document.

Step 2: Pick a format.

There are different formats you can use to write your document: step-by-step, hierarchical, narrative, etc. We recommend the sequential step-by-step format for its straightforwardness.

Step 3: Write the procedures.

Make sure your procedures are clear, concise, current, consistent, and complete.

Step 4: Review and update.

It’s important to review your SOP for any discrepancies and update them if necessary. Consider asking fellow leaders knowledgeable in procedure creation to read them over.

Why SOPs are Important in Manufacturing

Compliance with manufacturing SOPs is crucial for a number of reasons, including:

  • Prevents accidents and ensures worker safety
  • Promotes worker consistency
  • Improves product quality
  • Protects your business’s reputation

SOPs are a critical component of manufacturing operations because they provide a structured framework for achieving consistent quality, safety, and efficiency in the production process. They help manufacturers meet regulatory requirements, reduce errors, and ensure that employees are trained to perform tasks consistently and safely.

Digitizing Manufacturing SOPs with Connected Worker Solutions

Using connected worker technologies to create digital SOPs can significantly improve their impact on manufacturing by enhancing accessibility, effectiveness, and overall utility.

Through digitization and smart, connected worker technology manufacturers can improve SOPs with features like real-time access, remote collaboration and guidance, data-driven insights, workflow automation, enhanced training, traceability and compliance, and more. Essentially, with these advanced technologies, manufacturing organizations can augment and support their workers with optimized processes and SOPs creating an environment of continuous improvement.

Augmentir offers customized AI-powered connected worker solutions that transform how you write and create manufacturing standard operating procedures. Request a live demo today to learn more about why leading manufacturers are choosing our solutions to improve their manufacturing processes.

 

 

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Generative AI Learning Copilots: Transforming Learning as We Know It

Watch Augmentir’s presentation at Learning & HR Tech 2024 and see how Generative AI Copilots transform learning and development in manufacturing.

Generative AI in learning and development has started to shape the future of HR across the board including attracting, developing, engaging, and retaining talent.

AI has revolutionized how organizations approach:

  • Talent acquisition – for smarter recruiting
  • Talent development – for skills analysis and performance evaluations
  • Worker relations – capitalizing on its ability to personalize employee relations
  • Workforce planning – leveraging its ability to make sense of data to perform more accurate forecasting and capacity planning
  • People analytics – using AI to make sense of employee data from an engagement and skills optimization standpoint
  • Performance management – relying on it for benchmarking and progress evaluation
  • HR operations – leveraging AI’s ability to automate and support onboarding and offboarding processes
  • Learning and development – using AI in everything from content creation to delivering personalized and adaptive content

generative ai learning copilots

However, Generative AI in learning and development has yet to make a significant impact on employees where it matters the most – in the flow of work.

This is where Generative AI learning copilots and AI-powered connected worker solutions come in. Together these technologies are transforming learning for frontline workers, improving onboarding, enabling learning in the flow of work, and driving more efficient upskilling and reskilling.

Watch our full presentation from Learning and HR Tech 2024 “Generative AI Learning Copilots: Transforming Learning as We Know It”, on-demand below.

Key Highlights:

  • Generative AI in learning and development has started to shape the future of HR across the board including attracting, developing, engaging, and retaining talent.
  • Deskless workers make up 80% of all workers globally and are underserved from a learning and development perspective, with 78% feeling they don’t have the right amount of training to succeed.
  • Generative AI Learning Copilots can generate training content, translate languages, provide real-time feedback, give on-demand guidance and answers, and serve as a digital performance support tool.

Generative AI Learning Copilots for Deskless Workers

Deskless workers, often referred to as “frontline workers”, generally do not sit in front of a desk and make up about 80% of all workers globally, they are on the front lines – in factories, at retail counters, construction sites, hospitals, and more.

While frontline workers and activities have undergone dramatic changes over the past few years, they are still woefully underserved from a learning and development standpoint.

  • 78% of frontline workers feel they don’t have the right amount of training to succeed at work
  • 65% want information on-demand and “in the flow of work”
  • Only 12% of HR operations leaders are actually satisfied with their L&D processes in support of their frontline employees

The reality is that traditional onboarding and training practices have been proven to be ineffective, however, much like AI has historically been used to improve the efficiency and output of machines, we can do the same with our frontline workforce.

AI learning and development tools and GenAI assistants can help:

  • Identify areas for content improvement, and implement those improvements
  • Measure training effectiveness
  • Create personalized, job-relevant training and curriculums
  • Measure and improve workforce effectiveness

Managing Manufacturing Workforce Challenges with GenAI Learning Copilots

The workforce crisis in manufacturing is accelerating and at the forefront of the minds of operations and HR leaders.

In fact, even if every skilled worker in America were employed, there would still be 35% more unfilled job openings in the manufacturing sector than skilled workers capable of filling them. Deloitte predicts that the skilled labor crisis will cost manufacturers upwards of $1 trillion by 2030.

In 2019, the average tenure in manufacturing was 20 years, the average time in position was 7 years, and the average 90-day retention rate was 90%. As of 2023, however, the average tenure is 3 years, the average time in position is 9 months, and the average 90-day retention rate was 50%.

These are representative of drastically different manufacturing realities. The workforce of 2019 is not coming back, and neither will productivity, unless organizations make significant investments and strides in supporting frontline workers with the appropriate tools and training. Luckily, smart connected worker and generative AI technologies offer a path forward.

Generative AI helps manufacturers answer:

  • What is the skills inventory of the team that is in attendance today?
  • Who can/should perform this work?
  • Who would benefit the most from targeted training?
  • Where should they focus on for process improvement?
  • What type of training would give them the biggest return?
  • What training materials need Improvement?

Generative AI-powered copilots and digital assistants can take this further, allowing frontline manufacturing workers access to vast amounts of knowledge in the flow of work when they need it most, helping to predict and prevent skills gaps before they impact production, and to design efficient and personalized development curriculums to shorten the time it takes for workers to be effective and competent in their positions.

Interested in learning more?

If you’d like to learn more about Augmentir and see how our AI-powered connected worker platform improves onboarding, training, skills management, and other learning and development aspects across organizations, schedule a demo with one of our product experts.

 

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Why Integration is Key for Connected Worker Platform Success

Learn why integrations are key to the success of connected worker platforms, what systems should be integrated, and the benefits of a fully integrated connected worker solution.

Unlocking the potential of connected worker platforms becomes a game-changer when integrated with enterprise systems, giving them a live, closed loop connection to frontline processes and operations. This creates a truly connected enterprise that links diverse systems with the frontline workforce, paving the way for heightened efficiency, productivity, and safety.

connected worker platform integrations

However, a majority of connected worker platforms overlook the fact that connectivity doesn’t end with simply linking workers to their platform. They fail to recognize the immense benefits that live connections to enterprise systems of record bring to frontline business processes and activities.

Manufacturing success hinges on the seamless integration of connected worker platforms with legacy and enterprise systems to provide adequate support to frontline workers, giving them access to data and knowledge that can boost their efficiency and keep them safe.

Read below for more information on connected worker platform integrations; what they entail, which enterprise systems are essential for integration, and how AI-powered technology improves impact on frontline manufacturing activities.

Connected Worker Integrations: More than just an API

In manufacturing, it is critical that connected worker platforms are integrated with various enterprise systems to streamline operations and ensure that workers have the data and information they need at their fingertips. As critical as this is, most connected worker vendors believe that providing an open API is sufficient, and even boast that they integrate to enterprise systems, when in fact they place this burden on their customers.

Having an API is not enough

There are several not-so-obvious aspects to connected worker platform integrations, including:

  • Connected worker integrations with enterprise applications, even streamlined ones, have essential requirements such as logic that needs to be written, customized, run, and supported. Most, if not all, of this logic is initiated by the connected worker platform, propagating events and data from shop floor processes to the associated enterprise system of record.
  • Connected worker platforms with just an “API” require all of this functionality to be developed, hosted, and supported externally. The responsibility is then on the customer to build a custom product and select and support the hosting environment. This effort (building, hosting, and support) can cost between $50K and $150K to build and test, and then another $50K – $150K annually for 5 x 9 support. And, the customer is responsible for maintaining an SLA acceptable to the business (99.9% being typical).
Pro Tip

It’s critical that connected worker platforms include “platform-as-a-service” (Paas) capabilities that provide the ability to write, support, and execute both standard and custom integrations. These can be done by the platform provider, the customer, as well as third-party system vendors and system integrators. Providing PaaS capabilities puts the responsibility on the vendor for operating the integration service, and maintaining SLAs, geo-redundancy, disaster recovery, and privacy and security. In short, just saying “we have an API” places an undue burden on customers, and prevents building the sustainable connected enterprise necessary to remain competitive in today’s global economy.

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Which Enterprise Systems Should You Integrate

In any industrial environment, connected worker platforms should be integrated with various systems to support operations, help with cooperation and communication, and gain valuable insights into frontline manufacturing processes. These integrations streamline activities, improve efficiency, and provide a unified digital environment that empowers frontline workers.

This concept of a connected enterprise spans several initiatives within an organization: assets and equipment, the products being manufactured, the end customer, operations, workers, and the entire supply chain, and is highlighted below using the Industrial Transformation (IX) Reference Architecture from LNS Research.

connected worker enterprise system integration

Examples of enterprise management systems of record that are key to connected worker success and should be integrated are:

  • ERP (Enterprise Resource Planning)
  • EAM (Enterprise Asset Management)
  • HCM (Human Capital Management)
  • HR, Training, and LMS (Learning Management System)
  • QMS (Quality Management Systems)
  • MES (Manufacturing Execution System)
  • CMMS (Computerized Maintenance Management System)
  • Supply Chain Management

Enterprise systems such as ETQ, Workday, UKG, SAP, Oracle, IBM Maximo, Microsoft Dynamics 365, Salesforce, and ADP provide transformational value for a manufacturing company if they can be connected into frontline operations. By integrating connected worker platforms with these systems, manufacturers can create an interconnected environment that supports frontline workers and drives operational excellence. Ultimately, integration enhances collaboration, workforce visibility, decision-making processes, and overall operational efficiency, making connected worker platforms an indispensable component for manufacturing organizations.

Improving Integration Success Through Augmentir

At Augmentir, we see integrations differently than other connected worker platforms. Our rich history of building integrations in the manufacturing space enabled us to design a connected worker solution that easily, bi-directionally, and securely integrates the enterprise systems of record to create closed loop processes involving the frontline workforce.

Augmentir has internal PaaS services to run connectors that we build and support for popular enterprise applications like SAP, Salesforce, ETQ, Oracle, IBM Maximo, and more. Additionally, our PaaS enables custom integrations to be built and executed for custom, and niche applications. All third-party integrations running in the Augmentir connected worker platform carry the same SLA and geo-redundant support. By facilitating connected worker platform integrations with enterprise systems in this way, we have provided leading manufacturers with increased workforce visibility, improved productivity, digitized and standardized processes, enhanced training and collaboration, and more.

augmentir enterprise integration

Furthermore, because we are the leading AI-powered connected worker provider, we have brought innovative generative AI technologies such as AI-driven analytics, machine learning algorithms, NLP, predictive maintenance, and industrial AI copilots to improve connected worker integrations with enterprise systems, providing real-time guidance, enabling predictive analysis, and enhancing communication and collaboration among workers.

Schedule a demo to learn more about our AI-powered connected worker solutions and how they are drastically improving frontline processes, training, and manufacturing activities.

 

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How to Enhance Manufacturing Excellence with Mobile Operator Rounds

Learn how digital and mobile operator rounds make manufacturing inspections safer and enhance overall operational excellence.

Mobile and digital operator rounds significantly enhance manufacturing activities by providing real-time data collection, analysis, and decision-making capabilities. Applying mobile technology and digitizing operator rounds connects and empowers manufacturing workers and organizations with improved operational efficiency, equipment uptime, and drives continuous improvement initiatives, ultimately leading to greater operational excellence.

mobile operator rounds in digital manufacturing

Operator rounds in manufacturing refer to a systematic process where operators or technicians conduct routine inspections and checks on various equipment, machinery, and systems within a manufacturing facility. During operator rounds, operators inspect equipment, check for leaks, listen for unusual sounds, monitor gauges and indicators, and perform basic tests or measurements to ensure that equipment is operating as intended, identify potential problems or maintenance needs early on, and prevent unexpected downtime or failures that could disrupt production.

Operator rounds are an essential part of a preventative maintenance strategy, helping to improve equipment reliability, extend asset lifespan, and optimize overall manufacturing operations. They also provide operators with the opportunity to become more familiar with the equipment they are responsible for and to detect and address any safety concerns.

Read below to learn more about digital and mobile operator rounds, the benefits they offer versus traditional paper-based operator rounds, key aspects to include in an operator round checklist, and how AI-driven insights and connected frontline worker technology transforms the operator round process for enhanced results.

Paper-based Operator Rounds vs. Mobile and Digital Operator Rounds

According to Forbes, the average manufacturer encounters 800 hours of equipment downtime per year — more than 15 hours per week, with an estimated total cost of $50 billion per year. Further studies found that human procedural error contributed to 405 fatalities, 2,163 injuries, and over $150 billion in losses for manufacturers.

 

So why do many plant operators still use paper-based checklists and forms when conducting critical inspections?

 

In many cases, it is simply a matter of tradition, and when given the opportunity to make the process easier and more efficient with digital solutions, operators and manufacturers alike are eager to embrace the change.

Comparing paper-based operator rounds with mobile and digital operator rounds in manufacturing highlights several key differences in terms of efficiency, effectiveness, and overall impact on operational excellence.

Paper-based operator rounds in manufacturing can be boiled down to 4 main steps:

  1. Managers or supervisors create an operator round checklist/form
  2. The operator executes the round and writes the observations on a paper sheet
  3. In the instance of any uncertainties or issues workers need to stop the round and ask for assistance or guidance
  4. The worker then delivers the completed checklist to their manager, who incorporates it into an ERP system or other management tool

Compliance is difficult when using paper spreadsheets and word processor documents. Routes or routines that still use paper checklists must be manually entered into a spreadsheet or database. This not only creates double work, but issues such as:

  • Decreased visibility into facility-wide inspection activities
  • Inconsistent records
  • Lower anomaly detection and slower response
  • Remedial and follow-up procedures are not automatic
  • No access to immediate guidance or key information
  • Lack of operational context in potentially hazardous environments

mobile operator rounds maintenance

Mobile operator rounds and digital operator rounds, however, enable manufacturers and technicians to accelerate inspections, improve accuracy and compliance, and enhance operational excellence and efficiency through:

  • Real-time data collection
  • Immediate access to expert guidance or critical information
  • Automated alerts or notifications
  • Optimized processes and inspections
  • Remote collaboration
  • Enhanced compliance and digitized documentation

Connected devices enable operators to capture data, such as equipment readings, inspection results, and maintenance activities, directly at the point of operation. This eliminates the need for manual paperwork, reduces the risk of errors, and ensures that data is captured promptly and accurately. Additionally, digital operator rounds allow operators to access equipment manuals, schematics, and historical data instantly via mobile devices. This enables them to troubleshoot issues more effectively, follow proper procedures, and make informed decisions without delay.

Digital operator rounds systems can even streamline task assignment, tracking, and completion. Supervisors can assign tasks to operators, monitor progress in real-time, and prioritize work based on criticality and resource availability. This ensures that maintenance activities are performed efficiently and promptly. Overall, mobile and digital operator rounds empower manufacturing organizations to improve operational efficiency, maximize equipment uptime, and drive continuous improvement initiatives, ultimately leading to greater operational excellence.

Key Aspects of an Operator Round Checklist

An operator round checklist in manufacturing serves as a structured guide for operators to systematically inspect equipment, monitor performance, and identify potential issues during routine rounds. Here are key aspects to include in an operator round checklist:

  • Inspection Identification: Clearly list the equipment, machinery, or systems that need to be inspected during the rounds.
  • Visual Inspection: Include visual inspection items such as looking for leaks, cracks, signs of wear or damage, loose connections, abnormal vibrations, or any other visible abnormalities.
  • Safety Features: Verify the functionality of safety features and emergency shutdown systems to ensure compliance with safety regulations and protocols.
  • Functional Checks: Include functional checks to ensure that equipment is operating as intended. This may involve verifying that motors, pumps, valves, sensors, and other components are functioning properly.
  • Process Measurements and Readings: Include items that require measurements or readings, such as temperature, pressure, flow rates, voltage, current, or any other relevant parameters.
  • Quality Assurance: Ensure that quality checks are performed at each stage of the process and that products meet the quality parameters for each section.
  • Training and Qualifications: Ensure that operators conducting the rounds are adequately trained and qualified to perform the inspections and understand the importance of their role in equipment maintenance and reliability.
  • Special Instructions or Procedures: Include any special instructions, procedures, or precautions to be followed during the inspection, such as lockout/tagout procedures, safety protocols, or specific operating instructions.
  • Comments, Feedback, and Continuous Improvement: Encourage operators to provide feedback on the checklist and suggest improvements based on their observations and experiences during the rounds. Regularly review and update the checklist to incorporate lessons learned and optimize inspection processes.

Additionally, consider breaking down the inspection into specific points or components to be checked on each piece of equipment. This may include mechanical components, electrical systems, fluid levels, safety features, etc. Other potential aspects that can be considered or included are documentation requirements, reporting and communication specifications, and inspection schedule and frequency. By including these key aspects in an operator round checklist, manufacturing organizations can ensure thorough and consistent inspections, identify issues early, prevent unplanned downtime, and maintain equipment reliability and operational excellence.

Transforming Operator Rounds with AI-powered Connected Worker Technology

AI and smart connected worker technology are revolutionizing a wide range of manufacturing operational processes, including operator rounds. By introducing advanced capabilities for data analysis, frontline worker augmentation, and better connectivity, these emerging technologies are transforming traditional operator rounds allowing for enhanced predictive maintenance, remote guidance and support through Generative AI assistants, workflow optimization, and improved safety compliance.

With AI and smart connected worker technology, manufacturing organizations can optimize operator rounds, maximize equipment uptime, minimize maintenance costs, and achieve operational excellence in an increasingly digital and data-driven environment. Augmentir’s connected worker solution, for example, offers tailored solutions for improving a wide range of operational processes, including operator rounds.

Using Augmentir’s No-Code workflow builder, companies can quickly convert paper-based instructions and checklists to a digital format and tailor those digital instructions to meet the needs of individual operators with inline training, built-in collaboration, and troubleshooting support. Additionally, Augmentir has internal PaaS services to run connectors that we build and support for popular enterprise applications like SAP, Salesforce, ETQ, Oracle, IBM Maximo, and more. Allowing our system to easily, bi-directionally, and securely integrate the enterprise systems of record to create closed-loop processes involving the frontline workforce.

Schedule a demo to learn more about our AI-powered connected worker solutions and how they dramatically improve manufacturing operational processes like operator rounds through digital and mobile technology, enable personalized skills management and training, and optimize manufacturing activities.

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How to Digitally Enable Frontline Workers with UKG and Augmentir

Digitally enable frontline workers through UKG and Augmentir’s innovative partnership, leveraging AI and smart connected worker technologies.

Augmentir and UKG complement each other by providing an integrated mobile solution that digitally empowers frontline workers and drives operational excellence in manufacturing.

ukg frontline workforce connected with augmentir

UKG is a leading global provider of cloud-based human capital management and workforce management solutions for organizations to drive better business outcomes, improve HR effectiveness, streamline payroll processes, and enhance employee experience. Together with Augmentir – the leading AI-powered connected worker platform designed to digitize and optimize processes for frontline industrial workers, UGK digitally enables frontline workers to improve real-time communication, digital task management and standard work, training and knowledge sharing, and more.

Continue reading below to learn more about the benefits Augmentir and UKG bring to frontline workers and how together we are ushering in a new era of human capital management and an augmented connected frontline workforce.

Benefits of Connected Human Capital Management

Integrating Augmentir’s connected worker platform with UKG’s workforce management solutions offers several key benefits for empowering and enabling frontline workers:

  • Workforce Management Integration: Augmentir’s AI-powered connected worker platform integrates with UKG’s workforce management solutions allowing frontline workers to access scheduling, time tracking, and other UKG features directly within Augmentir’s platform. Workers can view schedules and manage workforce processes seamlessly through Augmentir’s user interface.
  • Real-time Communication and Collaboration: Augmentir and UKG offer tools for real-time communication and collaboration among frontline teams. Providing knowledge-sharing capabilities for frontline teams, and enabling seamless real-time communication, collaboration, and access to workforce information improves frontline adaptability and decision-making allowing for faster response and issue resolution.
  • Training and Skills Development: Augmentir and UKG facilitate training and upskilling of frontline workers. Augmentir’s platform delivers personalized digital work instructions and training content, while UKG provides learning and knowledge-sharing platforms. Together, they create a comprehensive training ecosystem for frontline staff.
  • Operational Insights and Continuous Improvement: Augmentir’s AI-based operational insights help identify opportunities for improving worker skills and driving continuous improvement. When coupled with UKG’s workforce analytics capabilities, organizations gain deeper visibility into their frontline operations to optimize productivity and processes.

Together, Augmentir and UKG create a powerful technology ecosystem that connects, empowers, and drives operational excellence for frontline workers across various industries by unifying their complementary digital workplace offerings.

Collaborating for the Augmented Connected Workforce of the Future

With UGK’s robust human capital management solutions integrated with Augmentir’s AI-powered connected worker platform, organizations enable an augmented connected workforce that is future-ready and equipped with the right tools for success.

UKG offers comprehensive workforce management solutions like UKG PRO, which includes features for scheduling, time tracking, payroll, and HR management. Augmentir allows companies to easily digitize complex frontline workflows and deliver personalized digital work instructions matched to each worker’s proficiency level. This ensures workers receive tailored guidance in the flow of work. Together, they give organizations a unified approach that augments and supports frontline workers by leveraging AI, real-time communication, comprehensive training solutions, and data-driven insights to ultimately drive improvements in productivity, efficiency, and better business outcomes overall.

Leading manufacturers that have deployed our augmented connected worker solution have seen impressive results such as:

  • 75% reduction in new hire training/onboarding time
  • 27% reduction in machine downtime using Autonomous Maintenance
  • 32% improvement in worker productivity

Furthermore, over 5,500 manufacturers globally leverage UKG solutions to create great employee work experiences, improve productivity, enhance compliance, increase operational performance, and more. By integrating UKG’s robust workforce management solutions with Augmentir’s AI-powered connected worker platform, organizations can create an Augmented Connected Workforce that is more efficient, productive, and engaged.

AI-Driven Connected Workforce Management Solution

AI-driven connected workforce management solutions like those offered by UKG and Augmentir provide several benefits for manufacturing operations including Intelligent Staffing and Talent Acquisition, Predictive Workforce Planning, Strategic Scheduling and Resource Optimization, Personalized Employee Development, and Increased Productivity and Cost Savings.

AI empowers manufacturers to forecast workforce needs accurately by analyzing frontline workforce data alongside historical data, market trends, and business objectives. AI-driven scheduling algorithms optimize Lean Daily Management by considering employee availability, skills, preferences, and other capabilities. This minimizes scheduling conflicts, reduces overtime costs, and ensures fair workload distribution while enabling real-time adjustments.

Additionally, with AI and connected technology manufacturing learning and development professionals can personalize employee training programs based on individual performance data and identify skills gaps for targeted upskilling or reskilling efforts. By leveraging AI, machine learning, digital workflows, and data-driven insights, modern workforce management solutions empower organizations to build a more efficient, agile, and connected frontline workforce capable of adapting to changing demands.

Interested in learning more?

If you’d like to learn more about how Augmentir and UKG work together to create a powerful digital ecosystem that streamlines operations, improves communication, and empowers frontline workers with the tools and information they need, schedule a demo with one of our product experts.

 

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WebexOne Recap – Elevate Your Workforce with Augmentir

Recently, the Augmentir team was excited to support WebexOne as a gold sponsor. It was great to participate in such an inspiring event, where collaboration and hybrid work were key themes throughout the sessions.

Recently, the Augmentir team was excited to support WebexOne as a gold sponsor. It was great to participate in such an inspiring event, where collaboration and hybrid work were key themes throughout the sessions.

During the event, our team had an opportunity to speak with industry leaders to discuss their top challenges and how Augmentir and Cisco together are helping shape the future of work in the manufacturing industry.

Shaping the Future of Work

Augmentir’s partnership with Cisco was built to address some of the top challenges in the industrial sector today. During the WebexOne event, Augmentir showcased how the Webex remote collaboration tool, Expert on Demand, and our AI-Powered Connected Worker Platform together deliver a unique combination of technology and tools necessary to help increase safety, quality, and productivity for frontline workers performing industrial jobs in manufacturing and service.

These themes were prevalent throughout the WebexOne event – using technology to unlock human potential and elevate today’s workforce.

Elevating Workforce Performance

Many of the themes discussed during the event focused on today’s changing workforce, and the unique needs of the “deskless” workers, who have been underserved by technology.  This is especially true in manufacturing, where businesses face a growing skilled labor shortage, retention, and worker engagement challenges, all while lacking the appropriate digital tools and data to effectively train and continually support their workers.

Augmentir’s suite of AI-powered connected worker tools help industrial companies understand their diverse workforce at an individual level, enabling them to reduce the effort it takes to onboard, guide, and support their workforce.

  • Improve job quality – Drive quality improvements by moving from paper-based to interactive digital work instructions augmented with rich media, contextual data, and mixed reality experiences, ensuring your workers always have the correct information on hand to make error-free and safe decisions.
  • Improve Worker Safety – In addition to running on any mobile phone or tablet, Augmentir and Webex are supported on the voice-enabled RealWear HMT-1 and HMT-1Z1 industrial headsets, offering hands-free operation that can be used in nearly any industrial environment. This helps workers stay focused on the task at hand to improve safety and efficiency.
  • Reduce operational costs – Identify areas where the largest improvements can be made within your workforce and across your organization with insights from Augmentir’s AI.

Elevating Hybrid Work and Collaboration in Manufacturing

Hybrid work and collaboration were also central themes during the event, and both are core to Augmentir’s combined solution with Cisco. Augmentir’s digital workflow tools enable rapid creation and delivery of augmented work instructions to help guide workers in day-to-day tasks. This value is extended with Cisco Webex Expert on Demand, which gives workers the ability to quickly connect and collaborate with remote experts wherever they are located.

Cisco also announced Webex Hologram during the WebexOne event. This new augmented reality meeting solution was noted by Jeet Patel, Executive Vice President and General Manager of Cisco Security and Collaboration, as an “industry first” – combining Webex meeting functionality with augmented reality (AR) hardware to create immersive 3D holograms of participants during meetings.

The Stakes Have Never Been Higher

As you can tell, WebexOne was a successful 2-day event with great conversations around collaboration and hybrid work. As Jeet Patel stated during the event, “The stakes have never been higher” in regards to your workforce and working smarter and more efficiently. It’s time to elevate your workforce with Augmentir’s AI-powered Connected Worker solution.