Shop Floor Data Capture: A Critical Step Toward Smart Manufacturing

Learn how shop floor data capture improves manufacturing efficiency, quality, and agility. Discover how Augmentir’s AI-powered connected worker platform transforms real-time data collection on the shop floor.

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Shop floor data capture is the process of collecting real-time information from manufacturing operations—including machine performance, labor activity, and production status—to improve visibility and decision-making. Connected worker platforms streamline and enhance this process by embedding data capture into digital workflows, enabling accurate, real-time input directly from frontline workers.

shop floor data capture by a technician in advanced manufacturing facility collecting data with a digital tablet Industry 4.0

Read this article to learn more about shop floor data capture in manufacturing:

What is Shop Floor Data Capture?

Shop Floor Data Capture (SFDC) is the process of collecting real-time operational data from the manufacturing floor. This includes tracking machine status, work order progress, labor inputs, quality checks, safety reports, material usage, and unplanned downtime—essentially, any data that reflects how work is being done in real-time.

Modern SFDC systems gather this information digitally using a combination of mobile devices, connected worker technology, sensors, connected machines (Industrial IoT), and software platforms, replacing traditional paper forms, spreadsheets, and delayed manual entry.

Why Shop Floor Data Capture Matters in Manufacturing Today

For manufacturers, every second on the shop floor counts. Without accurate, real-time insight into what’s happening, teams are forced to rely on outdated reports, gut feelings, or tribal knowledge to make decisions. This leads to:

  • Production delays
  • Low first-pass yield
  • Excessive downtime
  • Underutilized labor
  • Missed improvement opportunities

Shop floor data capture bridges the gap between what’s planned and what’s actually happening. When data is captured as work occurs, manufacturers gain the visibility needed to:

  • Identify inefficiencies immediately
  • Pinpoint training gaps or human error, which according to OSHA makes up 80-90 percent of serious injuries in the workplace.
  • Improve scheduling and resource allocation
  • Make data-driven decisions for continuous improvement

Who Benefits from Shop Floor Data Capture?

Shop floor data capture benefits multiple roles across manufacturing operations:

Operations Managers

  • Gain real-time visibility into production
  • Identify areas for process improvement

Supervisors & Line Leaders

  • Track shift performance and labor productivity
  • Ensure compliance with standard work

Continuous Improvement Teams

  • Analyze trends and root causes using accurate, structured data
  • Measure impact of Kaizen events or Lean initiatives

Quality Assurance

  • Detect deviations and non-conformances quickly
  • Link quality issues to specific operators, machines, or conditions

Executives

  • Align factory performance with strategic KPIs
  • Justify investments in digital transformation with hard data

Common Use Cases for Shop Floor Data Collection

1. Production Tracking

Capture cycle times, completion rates, and progress toward production targets.

2. Labor Time Reporting

Track how operators spend time on tasks, setups, changeovers, and idle periods.

3. Quality Checks

Real-time data collection with digital checklists and issue reporting—detect deviations and non-conformances quickly and link quality issues to specific operators, machines, or conditions.

quality control checklist with augmentir

Quality use case for shop floor data collection using the Augmentir Connected Worker Platform

4. Downtime and OEE Monitoring

Identify unplanned stoppages, categorize downtime, and improve OEE (Overall Equipment Effectiveness).

5. SPC Data Collection

Use modern software tools to support Statistical Process Control (SPC) data collection via mobile devices, allowing operators to input measurements directly from the shop floor. Visual dashboards and interactive SPC charts help teams quickly identify and respond to process variations.

6. Digital Work Instructions with Feedback

Capture data as operators follow digital work instructions—ensuring standard work is followed and insights are logged automatically.

7. Training and Skill Tracking

Use skills management tools to monitor how skill levels and training impact performance, and identify upskilling opportunities.

Shop Floor Data Capture is the First Step Toward Industry 4.0

Capturing accurate shop floor data is not just an operational improvement—it’s a foundational step in the journey toward smart manufacturing. By digitizing and automating data collection, manufacturers can:

  • Enable predictive maintenance
  • Support AI-driven decision-making
  • Improve workforce development strategies
  • Achieve greater agility in response to market changes

Whether you’re adopting Lean Manufacturing, Six Sigma, or Industry 4.0, real-time, accurate shop floor data is essential for success.

How Technology is Transforming Shop Floor Data Capture

Technology is revolutionizing how manufacturers collect and use data on the shop floor. Traditional manual methods—like paper checklists, spreadsheets, and standalone terminals—are being replaced by digital, connected solutions that enable real-time visibility, reduce errors, and unlock continuous improvement.

One of the most impactful advancements is the rise of Connected Worker Platforms. These platforms equip frontline workers with mobile devices, wearables, or voice-enabled tools that guide them through tasks while automatically capturing data in the flow of work. This eliminates the need for redundant data entry and ensures that information is accurate, consistent, and immediately available for analysis.

Adding to this transformation is the emergence of AI-powered digital assistants, such as Augie, Augmentir’s GenAI Assistant for Manufacturing. These AI tools analyze the data captured from the shop floor and deliver proactive insights, recommendations, and real-time support to workers and supervisors. Whether it’s identifying patterns in downtime, highlighting skill gaps, or surfacing quality issues, AI Agents enable a more intelligent, adaptive approach to managing operations.

 

using ai to improve manufacturing training

Key Technology Advancements Driving Change:

  • GenAI Assistants like Augie: Transform raw data into intelligent, actionable insights that drive continuous improvement and smarter decision-making.
  • Connected Worker Platforms: Digitize frontline work and embed data capture into standard processes.
  • Mobile and Wearable Devices: Allow workers to input data quickly and hands-free, improving efficiency and safety.
  • IoT Sensors and Smart Machines: Enable automatic capture of machine data without human input.
  • Cloud and Edge Computing: Ensure real-time access to data across facilities and roles.

By integrating these technologies, manufacturers are not only improving data collection but also building a foundation for a more agile, efficient, and intelligent factory floor.

How Augmentir Elevates Shop Floor Data Capture

Augmentir goes beyond basic data collection by embedding data capture directly into the flow of work through AI-powered connected worker tools. Rather than asking operators to fill out separate forms or spreadsheets, data is automatically gathered as workers execute tasks using digital work instructions, smart checklists, or mobile guidance.The

Augmentir platform is a suite of connected worker software tools that helps customers digitize and optimize all frontline processes including autonomous and preventive maintenance, quality, safety, asset management, and workforce training and development. The solution combines skills management, digital workflow, collaboration, and knowledge sharing to deliver continuous value in a wide range of verticals.

augmentir connected worker platform

At the core of this system is Augie, Augmentir’s Suite of GenAI tools. Augie continuously monitors captured data to deliver intelligent, context-aware insights to workers and supervisors—helping identify inefficiencies, recommend improvements, and provide real-time support when it’s needed most.

Key Capabilities:

  • Embedded Data Capture: Workers enter data naturally during task execution—no extra steps required.
  • Automated Time and Activity Tracking: AI accurately logs who did what, when, and how long it took.
  • AI-Driven Insights: Augie analyzes workforce and operational data to uncover skill gaps, detect process variation, and suggest workflow optimizations.
  • Closed-Loop Feedback: Capture feedback from the frontline to continuously improve instructions and processes.
  • Seamless Integrations: Sync with ERP, MES, or CMMS systems to create a unified data environment.
  • Real-Time Assistance with Augie: Augie acts as a digital assistant on the shop floor, guiding workers, surfacing knowledge, and enabling just-in-time learning and decision support.

With Augmentir, manufacturers move from reactive firefighting to proactive optimization—unlocking measurable gains in productivity, quality, and agility, all powered by real-time data and intelligent AI support.

Ready to Modernize Your Shop Floor?

With Augmentir, you can start capturing high-quality shop floor data in days—not months. Empower your teams with tools that make work easier while giving you the insight to continuously improve operations.

Request a demo or Contact us to see how Augmentir can help.

 

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Mastering the Golden Hour in Manufacturing: Boost Shift Startup Performance

Discover how to optimize shift startup performance during the golden hour in manufacturing – boost efficiency and drive productivity with connected worker technology.

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The Golden Hour in Manufacturing refers to the first hour of production after a shift begins, a line is restarted, or a process is changed over. It is a critical window of time where performance, quality, and productivity are closely monitored to ensure a strong, stable start to the shift.

golden hour in manufacturing

AI-powered connected worker solutions give you the digital tools to create a reliable, transparent, and data-driven shift handover — making your Golden Hour truly golden. No more missed info, no more guesswork, just smooth startups and better shift-to-shift alignment.

Read our article below to learn more about the Golden Hour in Manufacturing:

What is the Golden Hour in Manufacturing?

The Golden Hour in manufacturing is the crucial first hour at the start of a production shift, changeover, or restart. This period is treated as a high-priority window to verify that machines, materials, personnel, and processes are all operating correctly and efficiently. During this time, supervisors and frontline workers focus on identifying and resolving any early-stage issues—such as quality defects, equipment malfunctions, or supply shortages—before they can affect the rest of the shift. The goal is to ensure a smooth, consistent startup that sets the stage for high productivity and minimal waste.

This concept aligns closely with lean manufacturing principles, emphasizing proactive problem-solving, first-time quality, and continuous improvement. By closely monitoring performance metrics like first pass yield, cycle time, changeover time (a key performance indicator for quick changeover), and downtime during the Golden Hour, teams can make real-time adjustments and prevent small issues from becoming larger operational setbacks. Many manufacturers also use digital tools and connected worker platforms to standardize Golden Hour checklists, track startup performance, and support operator communication—turning this critical hour into a strategic advantage.

Pro Tip

Using digital tools and connected worker technology can help to standardize and optimize Golden Hour checklists, track startup performance, and support operator communication—turning this critical hour into a strategic advantage.

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Golden Hour: a Bottleneck and an Opportunity

The Golden Hour is a deceptively small window with an outsized impact. It’s when frontline workers receive their marching orders, assess equipment, respond to unresolved issues from the previous shift, and set the tone for productivity, safety, and quality. But for many manufacturers, this hour can be plagued by inefficiencies.

Bottleneck: Where the Golden Hour Goes Wrong

Here’s how the Golden Hour can become a liability:

1. Incomplete Shift Handover

Most shift changes rely on manual notes, whiteboard updates, or verbal exchanges. These are often:

  • Inconsistent or outdated
  • Lacking context (e.g., root causes, downtime justifications)
  • Not actionable for incoming workers

This creates information gaps that lead to confusion, delays, or rework.

2. Delayed Startup and Lost Time

Operators may spend 30–60 minutes just getting oriented:

  • Locating tools or materials
  • Checking machine status
  • Figuring out which tasks are highest priority

This lost time is rarely tracked, but it compounds over shifts, weeks, and quarters—significantly reducing overall equipment effectiveness (OEE).

3. Unresolved Issues Carry Over

When maintenance issues, quality concerns, or safety risks go undocumented or unaddressed, they often resurface during the next shift—now harder to track and fix.

4. Disengaged or Underprepared Workers

According to Gallup, employee engagement in the U.S. fell to its lowest level in over a decade in 2024, with only 31% of employees reporting being actively engaged at work. In manufacturing environments, this disengagement is especially visible during shift transitions—particularly among new or cross-trained workers. These employees often enter their shifts unsure of what’s expected of them, especially during the critical first hour. Without clear direction, proper onboarding, or real-time support, their uncertainty can quickly lead to avoidable errors, increased dependency on supervisors, and a noticeable drop in confidence and morale. This not only affects individual performance but can disrupt the flow of the entire operation.

Opportunity: A Strategic Window for Gains

When managed well, the Golden Hour becomes a strategic advantage that sets the foundation for a high-performance day.

1. Accelerated Ramp-Up Time

With the right systems in place, workers can:

  • Receive task assignments instantly
  • Access personalized, digital instructions
  • Know the status of machines and ongoing work within minutes

This cuts wasted time and increases output from the get-go.

2. Stronger Communication Between Shifts

Digitized, real-time shift reports ensure continuity by:

  • Highlighting unresolved issues
  • Providing historical context for recurring problems
  • Aligning everyone on goals and priorities

shift handover report - golden hour in manufacturing

Shift Handover Report using Augmentir’s Connected Worker Platform

 

This minimizes miscommunication and helps to improve shift handover.

3. Data-Driven Decision-Making

Supervisors and plant managers gain instant visibility into:

  • What happened last shift
  • What’s planned this shift
  • Where attention is needed now

These insights help allocate resources more effectively during the most time-sensitive part of the day.

4. Proactive Quality and Safety Checks

The first hour is a prime window to:

  • Identify anomalies before full-scale production starts
  • Catch quality issues early
  • Perform standardized safety walkthroughs

This proactive approach leads to fewer defects, reduced scrap, and improved compliance.

5. Frontline Worker Empowerment

When workers are equipped with the tools, context, and clarity they need right away, they feel:

  • More confident
  • More engaged
  • More likely to solve problems independently

The Impact Golden Hour has on Daily Productivity

The Golden Hour in manufacturing plays a crucial role in shaping daily productivity by establishing a strong operational foundation right at the start of the shift. When this first hour is managed effectively—through proper machine checks, material readiness, and operator alignment—it minimizes early disruptions and ensures that production ramps up efficiently. This proactive approach helps prevent issues from escalating, allowing teams to maintain a steady workflow and hit performance targets more consistently throughout the day.

Conversely, if problems arise during the Golden Hour—such as equipment malfunctions, quality defects, or unclear communication—they often cause delays and require rework, which can drag down productivity for the entire shift. By treating the Golden Hour as a focused period for startup optimization and problem-solving, manufacturers can reduce downtime, improve first-pass yield, and drive a more productive and predictable day on the shop floor.

How Smart Connected Worker Technology Improves the Golden Hour

Connected worker platforms digitize and enhance frontline workflows, enabling smarter, faster shift transitions. Here’s how:

1. Digital Shift Handover Logs

Replace static whiteboards and paper notes with real-time digital logs that:

  • Capture key insights from the previous shift
  • Automatically assign tasks
  • Flag unresolved issues or maintenance alerts

asset management with augmentir

2. Context-Aware Work Instructions

Workers receive personalized, on-demand instructions that adapt to:

  • Role
  • Skill level
  • Machine status
  • Environmental factors

This eliminates confusion and empowers workers from minute one.

integrated work systems with skills tracking and standard work

3. Data-Driven Shift Reports

Supervisors gain visibility into:

  • Performance trends
  • Downtime root causes
  • Operator feedback
  • Real-time metrics

This helps prioritize resources and make smarter decisions during the first critical hour.

 

4. Enhanced Collaboration & Communication

Connected platforms integrate chat, alerts, and escalation paths so teams across departments (maintenance, quality, operations) can collaborate instantly.

Optimizing the Golden Hour with Augmentir

In the fast-paced world of manufacturing, the first hour of every shift—the Golden Hour—can determine the trajectory of the entire day. It’s a window where clear communication, confident execution, and fast decision-making matter most. Augmentir, the world’s only AI-powered connected worker platform, is purpose-built to optimize this critical time by digitizing processes, guiding workers, and providing real-time operational intelligence.

Instead of relying on manual notes, whiteboards, or verbal updates, Augmentir transforms shift handovers into streamlined, digital experiences. Interactive, time-stamped logs capture production status, unresolved issues, and visual task assignments, ensuring incoming teams are aligned from the moment they clock in.
Workers no longer waste time figuring out what needs to be done. Augmentir’s intelligent platform delivers personalized work instructions, targeted task recommendations, and live feedback, helping every worker start their shift with confidence and clarity—whether they’re seasoned or new to the role.

For supervisors and plant leaders, Augmentir unlocks a deeper level of visibility into early shift performance.The analytics dashboard highlights inefficiencies, recurring downtime, and skill gaps that impact productivity—providing actionable insights right at the point of need.

Augmentir helps close the skills gap during this high-stakes hour. Integrated microlearning delivers training directly within the workflow, reducing ramp-up time and minimizing mistakes during the most impactful part of the day.

By turning the Golden Hour into a moment of alignment and acceleration, Augmentir helps manufacturers unlock new levels of efficiency, agility, and workforce performance—right from the very first minute of the shift.

Contact us today for a live demo.

 

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Continuous Improvement in Manufacturing: Embracing Innovation for Operational Excellence

Explore the fundamentals of continuous improvement, the challenges of traditional CI methods, and how technologies like Augmentir are transforming continuous improvement in modern manufacturing.

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In today’s competitive global market, manufacturers are under constant pressure to produce more efficiently, reduce costs, and deliver higher-quality products—faster than ever before. To stay ahead, continuous improvement is no longer optional; it is essential. This methodology, rooted in principles like Lean Manufacturing, Six Sigma, and Kaizen, focuses on incremental and ongoing enhancements in processes, productivity, and quality. But what sets the leaders apart in the modern era is how they leverage technology to drive and sustain these improvements at scale.

continuous improvement in manufacturing

In this article, we explore the fundamentals of continuous improvement, examine the challenges of traditional CI methods, and highlight how technologies like Augmentir are transforming continuous improvement in modern manufacturing.

The Core of Continuous Improvement

Continuous improvement (CI) in manufacturing involves systematically identifying, analyzing, and enhancing production processes. It is not just about big innovations; often, the smallest tweaks—reducing downtime, improving machine reliability, or streamlining communication—can yield significant ROI.

Key principles include:

  • Employee Involvement: Workers on the shop floor often have the most direct insights into inefficiencies and can be powerful agents of change.
  • Data-Driven Decisions: Improvements should be driven by measurable performance indicators.
  • Standardization and Feedback Loops: Once better methods are discovered, they need to be adopted, documented, and continuously reassessed.

While the philosophy is sound, many manufacturers struggle with implementation. And that’s where the problems begin.

The Problems with Traditional CI Programs

Despite decades of focus on Lean and Six Sigma, many CI initiatives fall short. Why? Because traditional CI programs are often hampered by outdated practices, lack of engagement, and poor data visibility. Here are some of the most common issues:

1. Siloed and Manual Processes

In many plants, improvement efforts are manually tracked—on paper, spreadsheets, or disconnected systems. This siloed data leads to slow feedback loops and inconsistent execution across shifts or facilities.

2. One-Size-Fits-All Approaches

Traditional CI programs often rely on standardized procedures that assume all workers have the same skills and experience. This ignores the wide variation in frontline worker proficiency and limits personalization in training or task guidance.

3. Lack of Real-Time Data

Many organizations make decisions based on lagging indicators like end-of-month scrap reports or audits. Without real-time insight into what’s happening on the floor, it’s impossible to react swiftly or identify the root cause of issues as they emerge.

4. Low Frontline Engagement

CI often becomes a top-down initiative driven by managers and engineers, rather than frontline workers. When operators aren’t empowered or incentivized to contribute, critical on-the-ground insights are lost.

5. Sustainability Challenges

Even when initial improvements are made, organizations often struggle to sustain gains. Without built-in systems for reinforcement, training, and measurement, improvements fade, and old habits resurface.

These problems don’t mean CI is broken—they highlight the need for modernization. That’s where connected technologies and AI come in.

Technologies Fueling Modern Continuous Improvement

To accelerate continuous improvement, modern manufacturers are increasingly embracing Industry 4.0 technologies—an approach popularized by German engineer and economist Klaus Schwab in his 2016 book The Fourth Industrial Revolution. This movement is reshaping manufacturing by integrating smart technologies that optimize production processes and enhance decision-making. Among the most impactful advancements are Connected Worker Platforms and Artificial Intelligence (AI), both of which are transforming how work is executed and improved on the shop floor.

the connected worker lifecycle and continuous improvement in manufacturing

Connected Worker Platforms

Connected worker platforms provide real-time visibility and data from the shop floor. These platforms link frontline workers with digital tools that enhance communication, guide tasks, and collect performance data. Key benefits include:

  • Standardized Work Instructions
  • Real-Time Communication and Support
  • Digital Training approaches that enhance corporate training methodologies, such as Training Within Industry (TWI)
  • Performance Data for Targeted Improvements

Artificial Intelligence (AI)

AI takes CI to the next level by analyzing massive amounts of operational data—spotting trends, predicting outcomes, and recommending optimizations. Benefits include:

  • Root Cause Analysis
  • Predictive Maintenance and Forecasting
  • Intelligent Guidance for Tasks and Training

Together, these technologies enable a dynamic, responsive CI process that adapts to real-world conditions and human variability.

Augmentir: Elevating Continuous Improvement with AI-Powered Connected Work

In the modern manufacturing landscape, tools that enhance worker productivity, decision-making, and operational visibility are essential. That’s where Augmentir stands out. As a next-generation Smart Connected Worker Platform, Augmentir is uniquely designed to empower frontline workers and enable continuous improvement at scale—using the power of artificial intelligence.

Unlike traditional connected worker solutions that merely digitize paper-based processes, Augmentir goes further. It not only captures data from the frontline—it makes that data intelligent, actionable, and personalized. With built-in AI capabilities, Augmentir helps manufacturers bridge the gap between people, processes, and performance improvement.

What Makes Augmentir Different?

At its core, Augmentir offers a suite of tools that digitize, guide, and optimize frontline work:

Personalized Digital Work Instructions

Augmentir enables the creation and deployment of dynamic, multimedia-rich work instructions. These are personalized based on worker proficiency, reducing errors and improving quality.

connected worker technology for safety compliance

 

Smart Workforce Management

With real-time skill tracking and performance analytics, Augmentir ensures that the right task is assigned to the right worker—improving efficiency and safety.

 

 

Industrial Collaboration

With manufacturing collaboration software from Augmentir, frontline teams can effectively collaborate and share information across across shifts, plants, and languages.

manufacturing collaboration software from augmentir for continuous improvement in manufacturing

Operational Visibility

Every interaction on the shop floor is captured and analyzed to surface trends, bottlenecks, and areas for improvement. Unlike traditional audits or passive reports, Augmentir offers continuous, real-time insights.

workforce performance insights with augmentir ai platform

Generative AI Assistant

Augie, Augmentir’s generative AI assistant, accelerates continuous improvement by delivering real-time insights, generating digital SOPs, and offering intelligent recommendations based on frontline data. By transforming operational activity into actionable guidance, Augie empowers teams to identify inefficiencies, reduce errors, and drive faster, more effective improvements.

augie generative ai assistant for manufacturing standard work

Continuous improvement is the heartbeat of modern manufacturing excellence. But in today’s environment, traditional methods alone are not enough. The path forward lies in combining proven CI philosophies with digital innovation.

With platforms like Augmentir, and tools like Augie, manufacturers can move from reactive problem-solving to proactive performance enhancement—empowering workers, accelerating learning, and ensuring sustainable results.

The future of manufacturing is connected, intelligent, and continuously improving.

 

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Breaking Down the Barriers to Digital Transformation in Human-Centric Operations

How do we enable humans to become a fully integrated part of manufacturing digital transformation, when their work data is so sparse?

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digital transformation

Much has been said and written about Digital Transformation in manufacturing, much less has actually been done about it.

Gartner defines Digital Transformation as “the process of exploiting digital technologies and supporting capabilities to create a robust new digital business model”. What isn’t said, and often not well understood, is that there are two fundamental aspects to Digital Transformation:

  1. The first is that all processes must be connected from end-to-end, with no digital air gaps. In this “Digital Thread” all links in the operations flow are seamlessly handed off from one system to another. In manufacturing this means from order receipt through shipment there is no paper in the process. Similarly in service operations, from ticket inception to closeout, there is no need for paper.
  2. The second is that all of the processes need to be both instrumented and agile. Instrumented so that you can get the data needed to apply Artificial Intelligence and Machine Learning (AI/ML) analysis to them, and agile so that you can improve them continuously over time.

Limitations of Automation in Manufacturing and Service

In high volume manufacturing scenarios, one of the unheralded benefits of automation has been to close the air gap between systems. Automation creates a machine-to-machine interaction without human intervention all the while generating the data required to feed to AI/ML systems. However, many business processes include activities that still heavily rely on humans to be accomplished and will for quite some time. Whether it is because the activity requires human dexterity, such as some assembly and QA procedures on a factory floor, or complex decision making, such as a field service engineer diagnosing a mechanical problem at a customer site. The costs, complexities, and capabilities of automation often make it infeasible for a large number of manufacturers and OEMs.

This creates a large barrier to Digital Transformation because a key component of digital transformation, the data regarding these operations, is only sparsely available. While high-level data, such as cycle time and yield on the factory floor or after the fact site visit write-ups by a service engineer, often exist, the detailed activities of the human worker are still a veritable “black box”. This is especially challenging for small to mid-sized businesses that overwhelmingly rely on human activities.

So where does that leave these companies — do they have no hope of leveraging AI/ML to continuously improve their business?

Closing the Air Gap of Human Operations

This is where Augmentir™ comes in. Our Connected Worker platform breaks down that barrier to true manufacturing Digital Transformation. Augmentir not only gives companies a way to rapidly author augmented work instructions but, when those instructions are executed by humans, very fine-grained data about the process steps – the tools being used, content being accessed, and results being generated – are captured in a non-intrusive manner and then fed back into the appropriate enterprise systems. Simply put, Augmentir closes the air gap of human operations, enabling humans, and the work they do, to become a fully integrated part of the digital thread.

Augmentir also solves the second, even more challenging aspect of Digital Transformation. It has has been estimated that data scientists spent 80% of their time cleaning and labeling data. Collecting and making sense of the sparse and noisy data streaming back from human activities has been a huge barrier to taking advantage of the advances in AI/ML technology to optimize human-centric operations. The Augmentir platform not only collects the fine-grained data, but cleanses, labels it, and then presents it to our embedded AI engine to develop unique insights into your operations. These insights help organizations identify where opportunities for improvement exist. This is the virtuous cycle of continuous improvement that is the hallmark of a “digitally transformed” organization.

Are you interested in learning how your organization can leverage augmented work procedures to close the air gap of human operations and continuously improve processes? Schedule your personalized demo and see Augmentir in action. 

Augmentir’s AI-Powered Augmented Worker Platform Improves Manufacturing Efficiency

The innovative producer of Hardened Workstations acknowledged that the AI-driven Augmented Worker platform has improved efficiencies and quality within a fortnight of its deployment.

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Augmented Worker

This article was originally published on AI Authority.

Leading manufacturer of operator interface systems and industrial displays, STRONGARM, has deployed Augmentir’s AI-Powered Augmented Worker Platform. The innovative producer of Hardened Workstations acknowledged that the AI-driven Augmented Worker platform has improved efficiencies and quality within a fortnight of its deployment. Currently, Augmentir, Inc. is a leading provider of Augmented Worker software for industrial companies.

Last month, Augmentir announced it has closed an oversubscribed funding round, led by Pritzker Group Venture Capital, with participation from Lerer Hippeau, current investors, and HOLT Ventures, the strategic venture capital arm of HOLT CAT.

STRONGARM has expanded the use of Augmentir’s AI-Powered Augmented Worker Platform across its operations, resulting in improved technician performance and training, better insight into job status, and improved quality.

What STRONGARM Achieved with AI-Powered Augmented Worker Platform

In an official press release, STRONGARM posted,

“Because the process was so easy, our technicians were able to quickly incorporate Augmentir into their daily operations, and the results were immediate – technician productivity improved, and inspection times went down. Furthermore, when one of our senior and most experienced technicians retired recently, we were able to onboard a new technician and trust Augmentir’s AI engine to guide him during the learning curve to get (the) product out the door at 100% quality so that we didn’t miss shipments. Once Augmentir’s AI engine determined that the worker had become proficient, it recommended that the instructions should be adjusted to enable him to complete the job faster while still meeting quality and safety goals. This has resulted in a 20% reduction in average build time in our most complex workstations.”

Steve Thorne, General Manager of Operations at STRONGARM stated,

“We chose Augmentir because their platform allows us to not only digitize and standardize on our manufacturing work instructions, but also to intelligently close the skills gaps when on-boarding new technicians. In addition, it’s AI-based ‘True Opportunity™’ system enables us to gain insight into how our technicians are performing, and autonomously identifies our largest capturable opportunities across our entire operation.”

“The use of Augmentir across our manufacturing operation represents an important step for us in our digital journey and continued commitment to quality and innovation in the products we build,” added Steve.

The Future of Manufacturing Lies with Digitally-Enabled AI and Robotics

STRONGARM designs and manufactures ergonomic and environmentally protected workstations for companies in a wide range of markets, including food, pharmaceutical, CPG, packaging, and transportation, with additional interface solutions for specialized verticals including STRONGARMenergy and STRONGARMhealthcare.

The company credits its long-term leadership position to its commitment to innovation. Since its 1990 founding, STRONGARM has maintained a robust “lot-size-one” offering wherein STRONGARM collaborates with clients, and then designs innovates, fabricates, and assembles these customer-specific products, all in-house.

Russ Fadel, Co-Founder, and CEO at Augmentir, said, “STRONGARM is a great example of a small, innovative manufacturing company that was able to capitalize on the emerging trends around Industry 4.0 and Digital Transformation.”

Russ added, “Augmentir was uniquely designed to meet the needs of industrial companies of all sizes, enabling even small to mid-sized manufacturing companies to get the benefits of Industry 4.0 today. Our SaaS-based ‘consumerized’ enterprise software approach makes trying, buying, and owning Augmentir simple, with free pilots, low IT support, and best in class usability.”

According to Thorne, STRONGARM started seeing value from Augmentir within 10 days of their Augmentir rollout. “The process for getting our operation set up with the Augmentir platform was easy and painless, with little required IT overhead,” stated Thorne.

STRONGARM plans to expand its use of Augmentir into the manufacturing operations of their ruggedized workstations used in the Oil and Gas industry.

The Augmentir Platform includes complete functionality that makes it easy for industrial companies to improve their operations across a range of manufacturing and service use cases. The Platform provides software that helps guide frontline workers with augmented, step-by-step-instructions, assist workers with live remove expert collaboration, and utilizes its AI engine to deliver organization-wide insights and recommendations that focus on improving the quality and productivity of frontline workers.

Augmentir is the first of its kind to combine enterprise Augmented Reality (AR) with Artificial Intelligence and Machine Learning (AI/ML) to empower frontline workers, helping workers perform their jobs with higher quality and increased productivity while driving continuous improvement across the organization.

Augmentir Welcomes Mike Carroll to Board of Advisors

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Augmentir welcomes Mike Carroll to our Board of Advisors! Mike is widely recognized as an industry trailblazer and visionary, with a proven track record of driving innovation, industrial transformation, and AI strategy.

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We’re excited to welcome Mike Carroll to Augmentir’s Board of Advisors!

A recognized leader in industrial operations, digital innovation, and workforce strategy, Mike brings decades of experience driving transformation across manufacturing and industrial enterprises.

augmentir welcomes mike carroll to board of advisors

Widely regarded as an industry visionary, Mike most recently served as Vice President of Innovation at Georgia-Pacific, where he led transformative initiatives across the company and its parent, Koch Industries. His leadership in AI strategy, operational excellence, and workforce enablement makes him a powerful addition to Augmentir as we continue to grow our AI-powered connected worker platform — helping manufacturers tackle their most critical workforce challenges.

A Career at the Intersection of Manufacturing, Innovation, and Industrial Transformation

Mike’s career spans key leadership roles where he has helped organizations modernize operations by aligning people, process, and technology. At Georgia-Pacific, he led enterprise-wide efforts in operations, engineering, and manufacturing excellence, creating more adaptive, future-ready workforces.

His expertise extends beyond technology adoption — encompassing workplace modernization and the human side of digital transformation. These experiences make him a valuable voice in the evolving conversation about the future of work.

Why This Matters Now

Manufacturing is undergoing a seismic shift. With aging workforces, widening skills gaps, labor shortages, and increasing production complexity, manufacturers are being forced to rethink how they engage, support, and train their frontline teams.

At the same time, emerging technologies like AI, connected worker platforms, and intelligent automation are opening new opportunities — but only when implemented with real-world operational understanding.

That’s where Mike’s experience is invaluable. Having led transformation initiatives from within the industry, he brings both a strategic lens and practical wisdom to ensure that workforce transformation remains central to industrial innovation.

Mike has a unique ability to connect operational goals with frontline execution. His strategic vision and practical insight will be a tremendous asset as we continue helping manufacturers digitize their frontline operations and unlock workforce potential through AI.

We see the future of industrial work now being realized by emerging AI approaches, utilizing generative AI knowledge management, and AI factory agents collaborating alongside humans on the shop floor. Augmentir’s focus on delivering an intelligent frontline operations platform goes beyond visualizing data to actually driving action. It digitally connects people, processes, and systems, enabling proactive management through intelligent workflows, digital task management, and continuous improvement tools. With Augmentir, data isn’t just displayed—it’s used to empower smarter, faster, and more effective operations.

“Augmentir isn’t just another layer of dashboards, it’s goal is to be a unified ‘single pane of glass’ that closes the loop between training and work execution, empowering frontline teams with AI-driven insights and augmented guidance to drive continuous improvement in safety, quality, and productivity. I’m excited to join a company that doesn’t merely digitize processes but learns from every action on the shop floor and delivers in-line support, whether through generative AI assistants or remote expert collaboration, so manufacturers can onboard workers faster, optimize skills, and unlock their full potential.”

– Mike Carroll

Driving the Future of Connected Work

At Augmentir, we’re committed to helping manufacturers digitize and optimize their frontline operations with AI-powered tools for skills management, digital workflows, industrial collaboration, and continuous improvement.

Welcoming Mike Carroll to our Board of Advisors is another step forward in that journey — strengthening our ability to serve manufacturers with both cutting-edge technology and real-world operational insight.

Please join us in welcoming Mike to the team!

 

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Solving the Single Largest Pain in Digitizing Frontline Work

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In conversations with our customers, a recurring theme emerges when discussing their transition to digital processes: the largest cost and burden often lies in the time and effort required to digitize existing paper-based materials.

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In conversations we have with manufacturing companies, a recurring theme emerges when discussing their transition to a paperless operation: the largest cost and burden often lies in the time and effort required to digitize existing paper-based materials.

digitizing frontline work with the augie gen ai suite

Standard Operating Procedures (SOPs), work instructions, and checklists are typically built over years, representing a significant repository of organizational knowledge. Converting these into digital formats while maintaining accuracy and accessibility can be daunting.

Customers frequently express concerns about the resource-intensive nature of this transformation. It’s not just about scanning documents; it’s about rethinking and structuring them for digital workflows. Many find themselves needing to allocate substantial time to review, update, and adapt content to ensure it aligns with current operational realities and integrates seamlessly into new platforms.

 

This challenge is real for any industrial company undergoing a transformation to digital manufacturing. It also represents an opportunity … and this is exactly why we created Augie.

The Power of GenAI in Digitizing Content

Generative AI (GenAI) has transformative potential for digitizing content by automating the conversion of paper-based materials into structured, digital formats. It can analyze and extract information from documents like SOPs, work instructions, or checklists, quickly translating them into editable, standardized templates. GenAI also enables content enhancement, such as rewriting for clarity, integrating visuals, language translation, or adapting content for specific workflows. By accelerating the digitization process and reducing manual effort, GenAI empowers organizations to transition to digital systems more efficiently and cost-effectively.

Augie, a suite of Industrial Generative AI tools from Augmentir, revolutionizes industrial digital transformation by combining advanced AI capabilities with practical, human-centric applications. Augie uses generative AI and the power of advanced Large Language Models (LLMs) to transform digital content creation, create adaptive workflows, provide real-time worker guidance, and analyze data to deliver actionable insights.

 

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Augie has been instrumental in helping us quickly transform our existing paper-based SOPs and training documents into interactive digital work instructions and learning tools. We’ve reduced our digitization effort from months down to days. This has streamlined our processes, reduced errors, and accelerated the upskilling of our workforce.

Digital Transformation Lead
Fortune 100 Food & Beverage Manufacturer

 

Augie for Procedure Creation

Augie is a powerful tool for accelerating the transition from paper-based to digital operations in manufacturing and industrial settings.

Quickly generate standard work procedures from Excel, Word, PDFs, images, or videos. The Augie Content Assistant takes your existing content and generates digital smart forms, checklists, and digital work instructions. Augie can summarize the exchange of tribal knowledge via collaboration and convert these to scalable, curated digital assets that can be shared instantly across your organization.

augie gen ai content assistant - convert video to procedure

Augie for Training Content

Augie, Augmentir’s GenAI assistant, makes it easier to convert paper-based information into tailored training content and quizzes for today’s less experienced frontline workforce. Augie automatically analyzes SOPs, work instructions, and other documents to create clear, simplified training modules. It generates interactive quizzes to reinforce key concepts and adapts learning materials to individual skill levels, ensuring workers engage with relevant content.

augie industrial copilot generative ai assistant for training and quiz creation

By streamlining this process, Augie reduces the effort and time required to create effective, hands-on training tools for workforce development.

Augie for Content Localization

Language translation and localization are crucial for ensuring work instructions and training materials are effective and accessible for frontline workers in manufacturing and any industrial setting. Providing materials in a worker’s native language increases comprehension, reduces errors, and enhances safety.

With Augie, content localization is easy. Augie’s content localization tools make work instructions and training materials more relatable and actionable. This investment fosters better workforce performance, inclusivity, and compliance with global standards.

augie gen ai suite assistant for content localization

The Next Phase of AI in Manufacturing is Here

Augie redefines the next phase of AI in manufacturing by seamlessly integrating generative AI into frontline operations to accelerate digitization, as well as enhance productivity and worker empowerment. Augie includes a complete suite of AI-powered assistants and AI services that help bridge the skills gap, accelerate onboarding, and ensure frontline workers are equipped with the knowledge they need to succeed.

The Augie Industrial Gen AI Suite transforms every stage of the Connected Worker Journey.

 

augie transforms your connected worker journey

 

Augie transforms every stage of the connected worker journey by providing a complete suite of AI tools that evolves alongside an organization’s needs. It begins with the digitization of processes and the conversion of static, paper-based content into dynamic, interactive digital workflows, making operations more accessible and efficient for frontline workers. As operations become connected, Augie leverages real-time data to deliver actionable insights, enabling companies to identify inefficiencies, improve workflows, and drive continuous improvement.

Beyond operational enhancements, Augie fosters continuous innovation through its extensibility and seamless integrations with other enterprise systems, creating a unified, scalable ecosystem that adapts to new challenges and opportunities. By addressing every phase of the connected worker journey, Augie empowers organizations to not only modernize their operations but also build a foundation for long-term success and innovation.

 

Now is the time to embrace the future of manufacturing—don’t miss out on the opportunity to empower your workforce and elevate your operations with Augie. Take the first step toward a smarter, more efficient manufacturing environment today.

 

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How Augmentir’s AI Delivers Transformational Value Across the Connected Worker Journey

Discover how Augmentir’s AI transforms the connected worker journey—boosting training, productivity, and continuous improvement across operations.

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In an era defined by digital transformation and workforce disruption, industrial companies are reimagining how they support their frontline teams. At the heart of this shift is the Connected Worker—a worker empowered by technology to perform safely, efficiently, and with confidence.

But enabling a connected workforce requires more than just digitizing procedures or implementing standalone tools. It demands intelligence embedded throughout the entire worker lifecycle.

the connected worker journey - powered by augmentir ai

That’s where Augmentir’s AI-powered Connected Worker platform shines. By infusing intelligence into every phase of the connected worker journey—from content creation to onboarding, daily operations, and continuous improvement—Augmentir delivers measurable gains in productivity, safety, and workforce engagement.

A Framework for Transformation: The Connected Worker Journey

The Connected Worker Journey consists of four critical, interrelated stages:

  1. Content Conversion & Creation
  2. Worker Onboarding & Training
  3. Operational Excellence
  4. Continuous Improvement

connected worker journey

At each phase, Augmentir’s embedded AI transforms outdated processes into intelligent workflows—helping organizations streamline deployment, scale training, and drive continuous value.

Let’s explore how.

1. Content Conversion & Creation

Laying the Foundation for Frontline Intelligence

Deploying modern Connected Worker software delivers ROI through a combination of features that support data collection, compliance, auditability, and data visibility for enabling continuous improvement.

For all companies, the Connected Worker journey begins with transforming legacy documents—SOPs, work instructions, training manuals, checklists, videos, and more—into structured, digital-ready formats that support the requirements above.

This means converting thousands (to tens of thousands) of legacy documents trapped in PDFs, Word docs, Excel files, Powerpoints, videos, and proprietary systems, all while trying to preserve their structure, intent, and compliance relevance. In the past, this process was typically manual, becoming one of the costliest and longest phases in the Connected Worker journey.

Augmentir, even prior to Generative AI (GenAI) era, has been a pioneer in providing tools to significantly reduce this effort even while meeting the three fundamental requirements of conversion:

  • Maintain the integrity of the form design: the format of legacy documents did not arrive by chance, rather they were the result of serious considerations for human factors. Arbitrarily changing these designs results in significant retraining of the frontline workforce, loss of usability, and potentially, significant operational qualification costs in regulated use cases.
  • Simplify the addition of data collection: make incorporating data collection throughout the form simple, efficient, and smart. Data collection offers the opportunity for smart validation, data driven conditional workflows, escalation, and continuous improvement.
  • Embed granular event tracking: Connected Worker ROI depends on the ability to provide compliance and auditability, which is enabled through granular event tracking. Additionally, continuous improvement relies on AI-optimized data from digital time and motion studies, which is automatically captured and processed through Augmentir’s patented True Productivity™ algorithm.

Today, general purpose GenAI tools offer the tantalizing vision that they can transform this process by accelerating the conversion of legacy digital content into, structured content suitable for Connected Worker use cases. There are examples where GenAI has been demonstrated as a general purpose solution to performing these conversions. Unfortunately, in each of the examples that Augmentir has reviewed, these tools met none of the fundamental conversion requirements.

create and convert content with augie as a first step in your connected worker journey

Included in Augmentir’s suite of Industrial GenAI tools, is Augie™ Content Assistant, which is purpose-built for Connected Worker use cases. Augie has been built with domain specific tooling which, when combined with advanced large language models (LLMs), delivers intelligent content that meets the foundational requirements of the Connected Worker space.

With the Augie Content Assistant, Augmentir turns the challenge of content digitization into a fast, AI-driven advantage:

  • 91% faster content conversion: What used to take hours now takes just minutes to convert a single document. When scaled across an organization’s entire repository of SOPs, work instructions, training materials, and more, this reduces the overall content conversion effort from months down to days.
  • Multi-format compatibility: Word, Excel, PowerPoint, PDFs, images, and narrated videos are seamlessly converted into native Augmentir content, complete with data collection and high resolution embedded event tracking.
  • Fidelity preserved: Structure, logic, and intent are maintained through AI-optimized prompts. This ensures that converted content mirrors the original format workers are familiar with—helping reduce change fatigue and making it easier for frontline teams to adopt digital workflows with minimal disruption.
  • Instant translation: Localize content quickly without compromising compliance or clarity.

augie gen ai content assistant - convert video to procedure

This is more than digitization—it’s intelligent transformation that enables data collection, auditability, and operational scalability from day one.

2. Worker Onboarding & Training

Adaptive Support That Accelerates Learning

Once your content foundation is in place, the next challenge is onboarding and upskilling your workforce. Traditional methods are static, generic, and fail to reflect real-time needs.

With Augmentir’s Augie Training Assistant and AI Agents, onboarding becomes a personalized, dynamic experience:

  • Tailored workflows: New hires are guided step-by-step based on their role, skill level, and assigned tasks.
  • Training in the flow of work: Instruction happens in real time, with guidance delivered during actual task execution.
  • Digital assistants ensure worker safety and compliance: Workers have natural language access to digital assistants to guide and support them while they work—enforcing safety, quality, and best practices.
  • Continuous adaptation: Augmentir’s True Opportunity™ AI continuously monitors skilling and reskilling performance and adjusts training content based on worker feedback and progression.

using AI for worker onboarding and training as part of the connected worker journey

This ensures faster ramp-up times, better comprehension, and more confident employees from day one.

3. Operational Excellence

Smarter, Safer, More Productive Frontline Work

With your workforce engaged and trained, the next step is supporting them during everyday operations. Here, Augmentir’s AI becomes a digital copilot—delivering real-time, personalized support in the flow of work.

With your workforce engaged and trained, the next step is supporting them during everyday operations. Here, Augie Work Assistant, which is fully customizable and extensible by customers, becomes a role-specific digital copilot—delivering real-time, personalized support in the flow of work.

augie industrial generative ai assistant

Key capabilities include:

  • Task-specific guidance: Augie delivers insight tailored to the person, the task, and the real-time conditions.
  • Role-Specific Digital SME: The Augie Work Assistant can be configured at the role level, provides always-on expertise that is tuned to needs to each person in each role—answering questions, flagging issues, and improving accuracy.
  • AI-powered integration: Embedded AI APIs automate documentation, resolve issues in real time, and enable intelligent quality checks.

The result? Fewer errors, faster resolutions, and safer, more confident workers.

4. Continuous Improvement

Closing the Loop with Actionable Insights

Continuous improvement (CI) doesn’t just happen—it requires the right data, insights, and tools to identify what matters most. Augmentir empowers teams to move from guesswork to precision by surfacing opportunities directly from real-world operations.

the difference between skills development and training in manufacturing

AI-powered tools include:

  • True Proficiency: Aligns training and performance data to uncover skill gaps and enhance learning programs.
  • True Opportunity: Pinpoints the highest-impact areas for improving quality, productivity, and safety.
  • Augie Data Assistant: Enables natural-language queries to quickly reveal trends, inefficiencies, or outliers.
  • Augie Content Assistant: Capture & Convert tribal knowledge embedded in informal collaboration into formal, reusable SOPs.
  • Augie Autonomous Agents: Automate repetitive tasks, monitor KPIs, and trigger proactive CI actions.

workforce performance insights with augmentir ai platform

Together, these tools ensure that continuous improvement isn’t a periodic initiative—it’s built into the fabric of daily operations.

AI That Delivers Real-World Value

Augmentir’s AI doesn’t just digitize work—it reimagines it. By embedding intelligence throughout the entire Connected Worker Journey, the platform empowers frontline teams to:

  • Onboard faster
  • Work safer and smarter
  • Learn continuously
  • Drive real business outcomes

With Augmentir, companies move beyond digital transformation toward AI-driven workforce transformation—turning every worker into a connected, empowered, and continuously improving contributor to operational excellence.

 

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