How to reduce downtime and increase productivity in manufacturing

Connected frontline operations platforms are helping manufacturers reduce downtime and provide a foundation for a holistic preventive maintenance strategy.

Downtime in manufacturing refers to a period of time when a production line or machine is not in operation due to maintenance, repairs, or other issues. This can result in a loss of productivity, increased costs, and missed production targets, and it is estimated that in the US alone it costs manufacturers around $1 trillion dollars per year. Not surprisingly, the biggest factors that contribute to unplanned downtime are human error and improper maintenance.

To minimize downtime, manufacturers are turning to digital technology to transform their frontline operations and provide a foundation for a holistic preventive maintenance strategy.

reduce downtime in manufacturing

Reducing downtime with a Connected Frontline Operations Platform

Manufacturers often implement Total Productive Maintenance (TPM) as part of a more comprehensive preventive maintenance approach. TPM is a strategy commonly used in manufacturing and production operations to improve the effectiveness and reliability of equipment, which in turn can increase productivity and reduce downtime.

Total productive maintenance strives to reduce workplace losses by placing the responsibility of basic maintenance upkeep on the primary equipment user: the machine operator. This preventive practice consists of “8 pillars” to help improve equipment reliability and elevate worker productivity:

Autonomous Maintenance as pillar of TPM

At the front of this framework is Autonomous Maintenance. Autonomous maintenance is a technique used in TPM that involves giving operators and other frontline employees the responsibility and authority to take care of their own equipment and work areas (e.g cleaning, safety checks, etc.). This can improve employee engagement by giving them a sense of ownership over their work and equipment, as well as a greater understanding of how their actions can impact productivity and quality. Additionally, involving employees in the maintenance process can lead to improved communication and teamwork, which can further enhance engagement.

This is where frontline operations platforms come into play.

Connected frontline operations platforms are digital software tools that can help standardize and improve the way operators perform maintenance tasks. They are used to improve communication, training, collaboration, guidance, and support for the operators.

Reduce machine downtime with Augmentir’s Connected Worker Solution

See how Augmentir can help you implement an effective autonomous maintenance program and optimize your frontline operations.

Get a Demo

downtime dashboard

Your connected workforce – a key to reducing downtime

Factory workers can have a significant impact on downtime in manufacturing. Whether it’s due to mistakes made by operators, non-optimal scheduling, or lack of communication, your workforce is at the center of your frontline operations. Factory workers can impact downtime in a variety of ways:

  1. Improper operation or maintenance: If factory workers are not properly trained on how to operate and maintain equipment, they may inadvertently cause downtime by making mistakes or not following proper procedures. Modern connected worker tools, like Augmentir’s connected worker solution, are increasingly being used to streamline training and digitize skills tracking to help ensure that the right people with the right skills are on the job.
  2. Safety incidents: Workers who do not follow proper safety procedures can cause accidents that lead to downtime while equipment is repaired or replaced. By digitizing safety procedures, manufacturers can ensure that workers perform the proper steps, and follow the proper protocols before performing a maintenance routine.
  3. Human error: Workers may make mistakes that lead to downtime, such as not properly setting up equipment or not noticing when a machine needs maintenance. Properly training employees on how to maintain and operate equipment can help to minimize downtime due to human error
  4. Quality issues: Workers may produce products that do not meet quality standards, which can lead to downtime while the products are reworked or scrapped.
  5. Lack of proper communication: Having clear and effective communication channels can help to quickly identify and address any issues that arise. Frontline communication tools like Augmentir can help improve communication and digitally record issues to better understand root causes. By identifying the underlying causes of downtime, manufacturers can take steps to prevent similar issues from occurring in the future.
  6. High turnover rate: High turnover rate can lead to a lack of experienced workers and can cause downtime while new employees are trained. While it’s difficult to completely prevent a high turnover rate, you can take measures to both expedite training for new hires, as well as create a more engaged, more empowered workforce. For example, Augmentir’s connected worker solution helps to accelerate new hire training and onboarding, and provides a skills management framework that helps to ensure that workers are excelling at their jobs.

It is important to note that factory workers are a crucial part of the manufacturing process and their role is vital for the success of the business. However, by providing workers with proper training, safety procedures, and communication channels, downtime in manufacturing due to human error can be reduced. Additionally, involving workers in the decision-making process and continuous improvement initiatives, can help to increase their ownership and responsibility towards the equipment, processes, and the whole factory’s performance.

Interested in learning more?

Augmentir is a connected worker solution that allows industrial companies to digitize and optimize all frontline processes that are part of their TPM strategy. The complete suite of tools are built on top of Augmentir’s patented Smart AI foundation, which helps identify patterns and areas for continuous improvement.

manufacturing kpi first time right

 

See Augmentir in Action

Five Steps to Reskill and Upskill Manufacturing Workers

Learn the five steps to upskill and reskill manufacturing employees. Find out the benefits such as improving productivity and retention.

While the terms ‘upskill’ and ‘reskill’ in reference to manufacturing workers are often used interchangeably, they are not the same.

Upskilling refers to cultivating a worker’s skillset to help them excel in their current role. Meanwhile, reskilling involves teaching an employee new skills in order to transition to a new role.

For example, a programmer can be reskilled to become a systems analyst. Or workers can be upskilled to manage technology as more jobs become automated.

Half of all workers will need to be upskilled by 2025 as more jobs become digitized, according to the World Economic Forum. Workers will take on more critical thinking and problem-solving roles, leaving technical tasks to artificial intelligence and machine learning. Furthermore, the growing skilled labor gap in manufacturing has created a workforce shortage, and upskilling and training are becoming necessary to ensure production capacity is met.

Explore the following topics below to learn more about upskilling and reskilling in manufacturing, including a step by step guides to reskilling and upskilling manufacturing workers.

What does upskill mean?

Upskilling involves evaluating an employee’s existing skills and helping them to advance in their current role. It helps facilitate continuous learning by providing training opportunities to develop employee skills.

It can involve refining either soft skills or technical skills to fill workplace gaps. For instance, emotional intelligence is a soft skill that can be honed in leadership roles. Similarly, technical skills are needed in many manufacturing positions. Working with technology is a must as companies automate more and more of their operations.

An HR representative with data analytics experience, for example, can hone their skills to take on more specialized tasks. This can consist of taking a class to gain more knowledge or attending a virtual conference to learn about industry-specific technology.

Upskilling staff can help your business stay on top of industry trends and pivot in an ever-changing digital landscape.

What is reskilling?

Reskilling involves learning new skills to move on to a new role within a company. It’s also a cost-effective alternative to hiring new employees.

For example, an electrician may have excellent planning and job estimation skills. The organization could choose to reskill that worker to an estimation position instead of hiring someone from the outside.

Or an employer could reskill a production assembler to work as a maintenance technician. The new role may require taking a series of training courses and completing certain safety classes or certifications.

Reskilling and upskilling are efficient ways to retain a manufacturing workforce. Both provide opportunities to help workers grow and advance skills. Learn how to upskill and reskill staff with the following steps.

How to upskill manufacturing workers

It’s important to have a clear plan to upskill manufacturing workers:

Step 1: Assess current skills.

It’s crucial to map employees’ current skills. This data will serve as the baseline for measuring employee progress.

A great way to outline worker skills is through a skills matrix, which digitizes and helps accurately track skills across your organization. This can help identify any skills gaps that exist in current departments.

skills matrix

Step 2: Access skills needed for the future.

After assessing current employee skills, it’s time to identify any skills needed for the future. Keep in mind that these must align with any changes expected to occur in the manufacturing industry or in your long-term business plan.

Step 3: Create upskilling goals.

Set employee-specific goals. For example, you may want each worker to take training courses to hone job-specific skills.

Step 4: Match workers with new learning opportunities.

Workers can develop skills through new learning opportunities. It’s important to offer training and development opportunities that help workers grow and foster their skills.

Step 5: Monitor progress.

By this stage, you should have mapped employee skills and outlined which ones are needed. It’s important to monitor any progress made. Organizations that digitally track employee skills can map “what the worker has been trained on” to actual job performance (“how the worker is doing”) to create a true representation of proficiency gaps and upskilling opportunities.

skills job proficiency mapping

How to reskill manufacturing workers

If you’re looking to reskill manufacturing workers, consider the following steps below:

Step 1: Identify what skills need cultivating.

Pinpoint which skills are the most valuable and create training programs to train workers on those skills. Think about which new roles need to be created.

Step 2: Integrate upskilling.

It’s vital to start training employees and offering resources to advance skills. For example, training your workers on how to operate digital tools or a specific piece of equipment can help them take advantage of promotion opportunities down the line.

skills job proficiency mapping

Step 3: Customize learning plan.

Develop a plan of core learning opportunities for any skillsets that are needed now or in the future. For example, you can customize learning plans to specific roles.

Step 4: Test and adjust.

Developing a perfect reskilling plan on the first try is no small feat. Be willing to acknowledge any mistakes and fix them.

Step 5: Invest in budget.

Allocating enough financial resources for reskilling employees is vital to company growth. Modify your budget to make reskilling a priority.

Benefits of upskilling and reskilling manufacturing employees

Workplace roles are changing and expanding in the age of automation. This change can bring about skill gaps that need to be filled for a business to stay ahead of the curve.

Upskilling and reskilling manufacturing employees has a number of long-term benefits for employers, such as:

  • Boosts retention. Investing in your employees’ skills development fosters better relationships. Workers who feel valued are less likely to leave. Improving retention can save businesses money on hiring and training new workers.
  • Improves morale. Businesses that offer training and development opportunities help their workers grow and move forward in the company. This can help employees feel like they’re working toward something and not staying stagnant within the company.
  • Improves quality and productivity. Beyond retention and morale improvement, upskilling and reskilling can have production benefits. A more skilled and trained workforce can result in improved quality, productivity, and efficiency throughout your organization.

Looking to improve upskilling and reskilling within your organization?

Augmentir’s suite of smart connected worker tools helps manufacturing organizations create a more skilled and productive workforce. Find out how our software can make it easier to reskill and upskill manufacturing workers in your organization. If you’d like a demo, let us know and we’ll be in touch.

How to Standardize Quality Assurance Procedures in Manufacturing

Learn how to standardize quality assurance procedures in manufacturing to improve overall quality and reduce errors.

It takes implementing just one wrong procedure for a product to end up defective and nowhere near ready for customer delivery. That’s why it’s important to standardize quality assurance (QA) procedures to ensure conformity on the shop floor and prevent product malfunctions.

But what is quality assurance? According to TechTarget, it is a process used to determine whether a product or service meets necessary requirements, in manufacturing specifically these are required standards for distribution. In a nutshell, QA procedures ensure customers receive quality products that are free of defects.

quality assurance procedures manufacturing

Learn how to standardize quality assurance procedures in manufacturing by exploring the following content:

What are quality assurance procedures?

QA procedures are a systematic process of establishing and maintaining set requirements for manufacturing reliable products and services. These procedures should be standardized by setting up a quality assurance system for workers to access. There, they can see how to complete certain tasks to avoid errors on the production floor.

Quality assurance methods can be categorized into three types, which we explain in the table below.

 

Type of QA methodDescriptionExample
Failure testingThis is the process of testing a product to see if it can withstand stress. The purpose is to identify any deficiencies.Manufacturers may place a product under heat, pressure, or vibration to test outcomes.
Statistical process control (SPC)SPC is an industry-standard practice for measuring and controlling product quality during the production process. Data is collected by measuring process inputs (dependent variables) in real time. This data is then transferred onto a graph with predetermined control limits based on how a type of product is expected to perform.A manufacturing line would apply statistical and analytical tools to monitor input variables and look for excesses or waste.
Total quality management (TQM)TQM is the idea that every employee, from assembly line workers to leadership, is committed to improving processes, products, and services.TQM may be implemented to raise overall productivity and make a manufacturer more competitive.

 

How to standardize quality assurance procedures

Quality assurance procedures help manufacturers develop products and services that meet customers’ needs and expectations. If implemented successfully, QA can catch any defects before they arise and substantially increase product quality.

It’s also vital to implement a quality assurance system to improve efficiency. Developing a unified system makes it easier to incrementally improve your production processes, and it’s essential for standardizing your quality assurance procedures.

Read on about the seven steps for successful QA implementation:

Step 1: Define Organizational Goals

Successful manufacturing QA begins by identifying how workers’ jobs are tied to an organization’s goals. It’s crucial for workers to know their company’s mission and how they fit into it. When employees understand how their individual goals relate to the organization’s goals, it can boost worker confidence — and in turn, production efficiency.

Step 2: Pinpoint Necessary Success Factors

It’s important to list the factors that make your quality assurance process successful. For instance, factors can include production processes, technical or customer support, and other things that make your organization great. Creating a list of major factors that contribute to company achievements will make it easier to update and manage those factors later on.

Step 3: Identify Your Customer Base

It’s vital to define your client case. If you know your customer, you’re more likely to create products and services that they would value.

Step 4: Gather Customer Feedback

Once you’ve established your customer base, it’s vital to incorporate what they think about your products and services. Frequent customer feedback can keep your quality assurance on track since it helps you identify and resolve product issues before they become critical problems. Reports can be gathered though surveys, email, phone, focus groups, or other methods. The goal is to achieve continuous feedback regardless of which methods you choose.

Step 5: Strive for Continuous Improvement

Quality assurance goes hand in hand with continuous improvement. The information you’ve gathered from customer surveys or other methods can now be used to implement any needed changes to your quality assurance process.

Continuous improvement can also be in the form of customer service training, changes to production processes, improvements to products or services, or anything that adds value to your organization.

Whatever you do, it’s crucial to study customer comments and use them to enhance operational procedures to ensure you’re delivering products that bring value and sell.

Step 6: Find QA Management Software

Once you’ve established the above steps, it’s time to start thinking about which quality QA software, or system, will help you better implement QA procedures. Picking the right software will aid with maintaining and improving production processes.

Step 7: Assess Results

Lastly, it’s important to measure your results. Your main goal is to ensure that your business meets the needs of each customer. Create measurable objectives for employees so that everyone knows what needs to be accomplished in a timely manner. If goals aren’t met, make sure workers are clear about what actions need to be taken to meet client satisfaction.

Take note: If your manufacturing firm does not reach its goals, it is hard to show a positive ROI to stakeholders. That’s why taking corrective action to meet company targets is more imperative than ever before.

Benefits of Implementing QA Procedures in Manufacturing

Quality assurance in manufacturing can offer a wide variety of benefits if management makes it a priority.

Some benefits of standardizing QA procedures include:

Cost-effectiveness: When done right, QA can prevent quality product issues before hitting the market. For instance, manufacturers won’t have to worry about scrapped parts, product returns, or other expenses due to poor-quality goods.

Greater workplace efficiency: Manufacturers will be able to better allot resources like time, money, and warehouse space if fewer product deficiencies exist. It boils down to this: it takes fewer resources to develop quality items if processes are in place to support the feat of QA procedures.

Enhanced Customer satisfaction: Customers will almost surely receive quality products in a timely manner if workers employ quality assurance techniques. If fewer product malfunctions exist, customers are more likely to keep coming back for more. In the end, it’s a win-win situation for both businesses and clients alike.

Industrial companies use Augmentir’s breakthrough system to standardize and optimize quality assurance procedures in manufacturing. With Augmentir, you will experience fewer errors and reduced product defect rates with our connected worker solution. Learn more about our quality use cases.

Contact us for a live demo to start optimizing your frontline operations today!

How to Build a World Class Supply Chain

Connected frontline operations platforms are helping manufacturers reduce downtime and provide a foundation for a holistic preventive maintenance strategy.

Your supply chain turns raw materials into finished products that meet customer expectations. It takes a whole network of people, from suppliers and manufacturers to distributors and partners, working together to produce the best quality products on the market. But how is it possible to build a “world class” supply chain?

According to Harvard Business Review, recent events such as the Covid-19 pandemic have exposed supply chain vulnerabilities and prompted a reevaluation of global approaches to improve resilience. Fortunately, the idea of a supply chain being world-class goes hand in hand with world class manufacturing, and there is a set of guiding principles to follow. Following them will help you successfully operate and manage a manufacturing firm that can remain competitive in the global marketplace.

world class supply chain

In this article, you’ll learn the five steps for building a world class supply chain and how Augmentir can help you transform the process:

  • 5 steps for making your supply chain world class
    • Step 1: Define clear objectives
    • Step 2: Gather necessary data
    • Step 3: Choose a supply chain management system
    • Step 4: Conduct supply chain network analysis
    • Step 5: Refine and improve
  • Elements of world class supply chain management and how Augmentir can help

5 steps for making your supply chain world class

Making your supply chain world class is about meeting or even exceeding customer expectations and delivering top-notch performance every time.

Step 1: Define clear objectives

Start by identifying overarching goals that will create consumer satisfaction. To help define those goals, ask yourself the following questions:

  • How much inventory needs to be stored, and where should it be?
  • Which modes of transportation would best balance out cost versus customer service objectives?
  • Which warehouses should administer which products to people?
  • How many warehouses are needed and what is the role of each?
  • What are the best routes to get products to customers the fastest?

Step 2: Gather necessary data

It’s important to gather the appropriate data to ensure that you’re meeting company-specific goals. For example, you may track data so you can keep an eye on product demand, transportation rates, lead times, and warehouse and inventory expenses.

Step 3: Embrace technology and digitalization

Leverage technology to automate manual tasks, improve visibility, and enhance decision-making. It’s crucial to pick software that addresses all of your production criteria and facilitates your unique business model. Adopt advanced supply chain management systems (SCM), enterprise resource planning (ERP) software, connected worker software, and warehouse management systems (WMS). Explore emerging technologies like blockchain, AI, and robotics to further optimize operations.

Step 4: Conduct supply chain network analysis

Once you’ve picked the perfect supply chain software, it’s time to analyze how well your production processes are faring. Consider evaluating if there are any gaps in product development and how long it takes for goods to be delivered.

Step 5: Refine and continually improve

Carefully examining your supply chain network and processes is a great starting point for becoming world class. But if you don’t make steady strides toward improvement, you’re left at a standstill. Things are constantly evolving in the manufacturing industry, so it’s helpful to check some of the following: production capacity, price fluctuations in raw materials, and any new large customer orders (especially if they were added in a different location).

Encourage a culture of learning, innovation, and continuous improvement within the organization. Promote employee engagement, provide training and development opportunities, and empower employees to contribute ideas for process optimization and supply chain innovation.

Continuous improvement is a must. So revisit your processes regularly, whether that’s monthly, quarterly, or annually.

Elements of world class supply chain management and how Augmentir can help

Implementing a world class supply chain management system can change the way manufacturers handle daily operations.

A world class supply chain usually is:

  • Customer focused: Consumers should be at the forefront of all production activities to ensure that goods are being made and sold in a timely, cost-effective manner.
  • Adaptable to changes: The manufacturing industry is changing fast, so manufacturers have to be responsive to changing customer demands, market factors, and more.
  • Collaborative: An effective supply chain fosters strong relationships among manufacturers, suppliers, distributors, and customers.
  • Highly efficient: Incorporating streamlined production processes, smart tech, and other resources is crucial to stand out among competitors.
  • Innovative: Constantly improving procedures drives growth and innovation.
  • Sustainable: Implementing sustainable techniques for cutting waste and maximizing productivity can lead to significant savings over time.

 

This is where Augmentir can help. We offer the world’s first AI-powered connected worker solution that advances how manufacturing firms handle day-to-day supply chain and other operations.

manufacturing kpi first time right

Our software lets you provide digital standard operating procedures for how to complete routine tasks and get the most out of worker output and productivity. We’ve helped frontline workers reduce training and rework time by 76%, and increase productivity levels by 36%.

With our software, you can build a world class supply chain that empowers workers across departments to make and deliver products of the highest quality. Request a live demo to learn more on how we’re the right fit for you!

How to Track Employee Skills in the Manufacturing Industry

Learn how to track employee skills in manufacturing and discover modern approaches to effective skills tracking.

In today’s manufacturing environment, it is daunting and time-consuming to keep track of employee skill levels across the many different job tasks. With the constantly accelerating rate of turnover in the workforce, Excel or paper-based skills tracking in manufacturing has become obsolete.

Leading manufacturers are now turning to smart digital technology to streamline skills tracking and connect it with frontline operations, giving them a competitive edge and boosting workplace safety productivity. Skills tracking software can be a great help to identify workers’ current skills and find any gaps. In a nutshell, such a tool helps automate, organize and simplify the process of evaluating employees’ skills and better understanding your workforce.

track employee skills in manufacturing

Learn more about how skills tracking is changing and the importance of integrating skills management into the flow of work by exploring the following topics:

Five approaches to effective skills tracking in manufacturing

According to a recent survey by McKinsey & Company, companies reported that tracking and validating skills and competencies was their top talent challenge.

Effective skills tracking can improve safety, productivity, and worker performance by helping match the right people with the right tasks. For any organization, there are multiple methods and tools that can be used to track the skills of your workforce:

1. Direct assessment

This approach focuses on one employee directly assessing another. This may be done as a form of peer review between employees or by a manager.

2. Self-assessment

This approach consists of employees conducting self-assessments of their skills and qualifications through surveys every few months.

3. Anonymous peer assessment

This approach involves coworkers anonymously assessing each other’s performance on projects or other tasks.

4. Skill assessment using HR or learning systems

This type of assessment can be done using an HR system (or a Learning Management System) to assess and update employee profiles based on training completed. For example, workers can report any courses finished, track their training data or report new certificates.

5. AI-based skills tracking software

Any of the above 4 methods are commonly used, however, the increasing workforce variability, absenteeism, and turnover is forcing new requirements. Increasingly, manufacturers are turning to AI-based software solutions to help digitally track and manage skills, and connect them with work execution.

HR/Learning systems or standalone skills tracking software solutions that attempt to automate skills tracking fall short of meeting the needs of today’s manufacturers because they do not connect the “skills that workers know” with the “work being done”. These standalone solutions may have been ideal for the stable, unchanging workforce of the past, but they are not suited for today’s era of high workforce variability.

skills and work

An integrated, closed-loop skills management system is the solution for this era of high workforce turnover and absenteeism. Skills management solutions that combine skills tracking capabilities with AI-based connected worker technology and on-the-job digital guidance can deliver significant additional value. Data from actual work performance can inform workforce development investments allowing you to target you training, reskilling, and upskilling efforts where they have the largest impact.

Benefits of skills tracking in manufacturing

Tracking skills in manufacturing can help identify the skills your employees already hold and those they still need to learn to properly do their jobs. Furthermore, using AI-based connected worker solutions, organizations can digitize and easily manage skills tracking and training programs and connect them with frontline operations.

Some benefits of tracking your employees’ skills using this approach include:

1. Boosts productivity on the shop floor

An organization’s commitment to cultivating its team’s skills can influence their attitudes toward the job. A worker is likelier to perform better when valued and appreciated. Skills tracking also ensures that workers are qualified to perform their job.

2. Ensure safety

Solutions that close the loop between training/skills and the work being done allow organizations to validate at the time of work assignment who has the skill level to safely perform a specific task. This helps to mitigate risk and ensure safety.

3. Intelligently assigning work

Ensure the right person is assigned to the right job. Manage work assignments based on skill level, endorsements, and actual job performance.

4. Closes the skills gap

Tracking skills is a great way to identify gaps between the skills employees already have and the skills they need. With this information, the company can arrange for additional training or other ways to invest in their employees. Keep in mind that as your manufacturing organization evolves and grows, so should your employee skillset.

5. Boosts internal communications

Employers who actively develop their employees’ skill levels are likelier to retain them. Tracking skills can also motivate and spur connections with team members.

6. Identify upskilling or reskilling opportunities

Use data from actual work performance, combined with an employee’s current skills and endorsements to inform your reskilling and upskilling decisions.

7. Enhances competitive edge

Although the purpose of effective skills tracking is to aid in worker growth and development, a byproduct is a stronger, more competitive organization as a whole. Knowing where improvements need to be made can close any learning gaps and boost the overall success of a company. Optimizing your workforce can help improve productivity in every department, giving your company a competitive edge in today’s market.

Features to look for in skills tracking software

Having the right features for skills tracking in manufacturing can help a company be more productive and efficient. This type of software should help manufacturing facilities no only identify, assess, track and cultivate employee skills, but also improve operational safety and performance.

It’s important to look for the following features when deciding which software is right for you:

Training management
This feature helps businesses see how their teams are progressing and evaluate whether training opportunities are making an impact. It helps store employee training records for real-time access and evaluation, and measure training effectiveness based on actual job performance.

Certifications management
This feature helps employers manage employee certifications. If a worker’s certification is expiring, the software’s tracking functions should easily notify the parties involved.

Skills tracking integrated into the flow of work
Skill levels and current endorsements ensure that workers can perform tasks safely and correctly and, therefore need to be considered at the moment of work assignment and again at the moment of work execution.

Live dashboard
Skills tracking software with customizable dashboards offer a real-time view of employee skills, qualifications, and any skill gaps that may exist. Managers will have a better idea of where to allocate resources to train employees and who is a better fit for a role.

intelligently assign jobs

 

Learn how Smart Skills Management software is helping manufacturers bridge the gap between training, skills, and work to build a more resilient and agile workforce.

Download our latest eBook – The Future of Work: Connecting Skills Management with Standard Work.

Download the eBook

 

How to Find the Best Skills Tracking and Management Software

Smart Skills Management software is helping manufacturers bridge the gap between training, skills, and work to build a more resilient and agile workforce.

Skills management and tracking software helps manufacturers identify and track employee expertise. You can map skills from a centralized library to individual workers, analyze the performance of your teams, and fill any skill gaps that exist.

These smart insights can help businesses improve their talent management strategy, including training and development programs and recruiting opportunities.

If you’re interested in learning how to find the best skills tracking software, explore this article as we cover:

  • Benefits of skill management and tracking software
  • What to look for in tracking software
  • FAQs about skills tracking and management tools
  • Why Augmentir

Benefits of skills tracking and management software

Skills management involves identifying workers’ expertise and experience to determine whether they’re a right fit for a role, which areas need improvement, and how to best facilitate learning opportunities. A reliable skills tracking and management software solution lets you keep track of what your employees can and can’t do, and integrates that information with the actual work being done.

Here are a few reasons why you should invest in a tracking tool:

Enhanced training and development programs: Improve employee engagement by making sure courses and training opportunities are relevant to the jobs they perform. Management software makes it easier to assign employee courses that are appropriate and timely, and then track each individual’s training progress.

A more productive workforce: Employees who have access to training resources can further develop their skills to better perform assigned job duties and maximize output. This will empower workers to strive for continuous improvement and grow in their roles.

Improved retention: Offering continuous development and training programs can help your employees feel appreciated and taken care of. In return, they are more likely to stay and do a good job. Considering that turnover rates cost manufacturing firms an overwhelming amount, it’s critical to invest in programs that will improve retention rates.

What to look for in tracking software

Knowing how to effectively track employee skills can be challenging, but the right software can ease the burden. It makes it easier to identify who is lacking which skills and how to best close the gap.

Unfortunately, standalone skills management software solutions that attempt to automate skills tracking fall short of meeting the needs of today’s manufacturers because they do not connect the “skills that workers know” with the “work being done”. These standalone skills management solutions may have been ideal for the stable, unchanging workforce of the past, but they are not suited for today’s era of high workforce variability.

Skills management solutions that combine skills tracking capabilities with connected worker technology and on-the-job digital guidance can deliver significant additional value. Data from actual work performance can inform workforce development investments allowing you to target your training, reskilling, and upskilling efforts where they have the largest impact.

When looking for the best skill management and tracking software, its critical to make sure it can:

  • Keep a centralized database of competencies
  • Pinpoint worker skill gaps
  • Let management look for employees with specific expertise
  • Track the skills of individual employees in a centralized database
  • Intelligently assign work based on true worker skills and competencies
  • Personalize on-the-job guidance based on worker skills and experience
  • Create reports or dashboards to study competencies and skill gaps across departments

AI-powered software enables managers to filter through employee databases by skill to assemble teams best suited for a project.

 

skills tracking software

 

Skill management solutions should also integrate with core human resources software to offer seamless sharing of employee data. Some tools may even work in tandem with corporate learning management systems to provide access to educational content that could help workers develop new abilities.

Lastly, HR can use skill management software to make it easier to follow compliance regulations that require evidence of employee capabilities or certifications. For example, a health manufacturing facility may need workers to upload certain certifications to show proof of compliance.

FAQs about skills tracking and management tools

How do you keep track of employee skills?

You can track employee skills using software that manages worker competencies. These programs should allow you to build customized job profiles, create reports to study competencies, and fill skill gaps.

What is skills software?

Skills software is a tool that helps manage and keep track of worker expertise and experience. It’s used by businesses to optimize job performance and boost worker productivity.

Should I invest in skills tracking software?

Manufacturing facilities can benefit from investing in software that provides an easy-to-use centralized database of worker profiles, training resources, and much more.

Why Augmentir

Augmentir can help manage the skills of your workforce with its AI-powered connected worker solution. Our skills management tools create visibility at all times to optimize training programs, track individual and team progress, and initiate more targeted training. Check out our live demo.

 

Learn how Smart Skills Management software is helping manufacturers bridge the gap between training, skills, and work to build a more resilient and agile workforce.

Download our latest eBook – The Future of Work: Connecting Skills Management with Standard Work.

Download the eBook

 

Manufacturers are onshoring at a rapid pace. Here’s how to get ready for this growing trend.

Augmentir’s take on the trending Workforce Institute’s staggering survey numbers.

Do you remember when offshoring–the outsourcing of production internationally–was once considered the “gold standard” for manufacturers because of reduced costs? Funny how things change. We can partly thank the global pandemic for this. Reshoring, also referred to as ‘onshoring’, in manufacturing is now the way to go–the apparent panacea to supply chain disruptions and a healthier economy. This should have manufacturers cheering and dancing in the streets, right? Not so fast. We’ve also got a massive labor shortage to deal with. But don’t fret. There are solutions to be found, and they happen to exist in software tools already being embraced by organizations on their journey to digital transformation.

The perks and pressures of onshoring in manufacturing

If your organization isn’t already thinking about onshoring its operations, maybe you should be. Onshoring in manufacturing means greater resiliency, agility, and sustainability by shortening the distances between process and delivery. Less travel means reduced emissions and adherence to ESG standards. Reshoring addresses issues associated with shipping costs, lead times, and new regulations. Working in familiar markets can help identify supply and demand trends more accurately. National employment rates are likely to increase when hiring residents and working with other domestic business partners.

But labor shortages and the variability of today’s workforce have not made reshoring an easy shift. So while there is tremendous opportunity to bring production home, the lack of affordable and skilled labor is having a tremendous impact on our domestic production capacity.

Here’s how you make onshoring work for you. First, stop thinking the old way of recruiting, training, and retaining workers will still work today.

Work with what you’ve got

What’s wrong with training today? Yes, training programs can help improve worker knowledge and skills development. But only if they are meeting the unique needs of individual workers with content-rich, high-impact learning and hands-on training programs. Forget those standard training programs–they are useless in the face of the variable workforce we have available today. The workers you can find are showing up with a mixed bag of experience and skills. That doesn’t have to be a disadvantage anymore. Because there is a smarter way to train and optimize the skills of each of those workers to meet productivity goals individually and fulfill the potential for your organization’s production capacity.

Smart digitization is the ticket to effective onboarding, training, and more–from hire to retire

“The secret of change is to focus all your energy not on fighting the old, but on building the new.” – Socrates

This new era of workforce instability is forcing manufacturers to change. It’s forcing them to turn to digital technology and look at smarter ways to hire, onboard, train, and retain their workers. At Augmentir, we call this Smart Digitization.

What do we mean by ‘smart’ digitization? Smart digitization involves adopting modern, digital tools, mobile technology, and supporting workers throughout their entire lifecycle.

smart digitization throughout worker lifecycle

 

Modern connected worker tools are at the core of the solution that supports workers throughout their employment, from training to troubleshooting in real-time to ongoing learning and development. If you look at the entire employee lifecycle, this means:

  1. Using software tools to digitize and automate onboarding and skills tracking to help get workers operational faster, regardless of their skill and experience.
  2. Once on the job, digitizing and personalizing work instructions based on the individual needs of the worker – whether they are a novice worker or an expert.
  3. Proving instant access to support, within the flow of work.
  4. And finally, using an AI-based system to analyze how workers are performing on the job, and intelligently targeting upskilling and reskilling based on actual work performance.

Workers have access to a suite of digital tools and knowledge resources at their fingertips – digital work instructions, collaboration, and support tools to guide them on the job and quickly problem-solve complex tasks, allowing them to do their personal best.

For employers, this means not only more engaged and collaborative workers, it also means deeper insights into work performance that can help drive continuous improvement efforts.

skills job proficiency mapping

AI-based smart insights intelligently optimize workers’ performance by identifying and tracking their skills in real-time. Smart insights pull from these performance metrics and learn to prompt workers who need new training programs or work opportunities, continuously upskilling and reskilling.

It’s the advanced medicine needed to maximize productivity and operational health.

So as you plan to bring more of your production back home, make sure you’re ready to seize the opportunity and address the challenges of a restricted labor market at the same time.

 

Find out how and why so many manufacturers are turning to Augmentir to turn their workers into efficient, productive, and long-term assets for their businesses.

Check out our latest webinar – Smart Digitization of Frontline Workers to learn more.

Watch the Webinar

 

Autonomous vs. Preventive Maintenance

Connected frontline operations platforms are helping manufacturers reduce downtime and provide a foundation for a holistic preventive maintenance strategy.

Autonomous and preventive maintenance are two manufacturing strategies for maintaining machinery on the shop floor. The main difference between the two is that autonomous maintenance (AM) places greater responsibility for equipment upkeep on operators, while preventive maintenance (PM) is carried out by maintenance workers. Both autonomous and preventative maintenance strategies benefit from smart, connected worker technologies, although in different ways.

autonomous vs preventive maintenance

AM, for example, focuses on training machine operators to be the point of reference for cleaning, inspecting, and making minor repairs on the spot. This approach aims to empower operators to take the initiative in monitoring their equipment and identifying issues early on. By introducing smart, connected worker technology, like Augmentir’s suite of connected worker tools and closed-loop autonomous maintenance solution, manufacturing leaders can give operators more control over inspections and help intelligently guide and support operators, resulting in minimized machine downtime.

PM, on the other hand, consists of scheduling regular maintenance activities like part replacement, lubrication, and calibration. Workers tasked with PM ensure equipment remains in tip-top condition, which helps to prevent future breakdowns. The goals of this strategy are to avoid machine downtime and reduce the need for unplanned repairs. Smart, connected worker solutions improve the quality, transparency, and efficiency of both autonomous and preventive maintenance and repair procedures by standardizing and optimizing maintenance procedures.

You can learn more about autonomous and preventive maintenance by exploring the following sections:

What’s autonomous maintenance and its advantages?

Autonomous maintenance involves machine operators tackling basic equipment upkeep tasks to ensure that everything runs smoothly on the production floor.

When implemented, AM can yield a number of benefits:

  • Reduced equipment downtime: Conducting routine upkeep activities can prevent breakdowns and limit the need for unplanned maintenance.
  • Greater machine reliability: Operators who are trained to maintain their own equipment are more likely to pinpoint problems before they lead to machine failure.
  • Prolonged lifespan of machinery: Equipment that is maintained will last longer and require fewer repairs or replacements.
  • More operator involvement: Operators who take an active role in preserving their machinery feel empowered.
  • Increased safety: It’s easier to troubleshoot potential hazards before they turn into accidents when operators frequently inspect and maintain their equipment.
  • Cost-effectiveness: Reducing unplanned maintenance can save manufacturers significant money over time.

When coupled with smart, connected worker technology and AI-driven analytics, AM’s benefits are further enhanced. Digitizing autonomous maintenance processes increases standard work adherence, clears defects faster, and improves auditability. Connected worker technology enables operators to share knowledge and gives them access to the resources they need right when they need them.

autonomous maintenance

 

What’s preventive maintenance and its benefits?

Preventive maintenance focuses on performing routine equipment upkeep tasks at scheduled intervals. The goal is to avert equipment failure and limit unplanned downtime or repairs.

The benefits of having dedicated workers perform preventive maintenance are:

  • Enhanced machine reliability: Regular maintenance increases the odds of identifying and fixing problems before they turn into mechanical failures.
  • Decreased downtime: Conducting routine upkeep at scheduled times can decrease unplanned maintenance and increase production efficiency.
  • Greater compliance: PM can help manufacturers better comply with regulatory requirements to prevent unnecessary penalties for non-compliance.
  • Better planning protocols: Recruiting specialized maintenance personnel with extensive training on machine upkeep and repair can lead to better planning and allocation of resources.
  • Increased safety: Training workers on basic maintenance techniques ensures that deficiencies are addressed in a timely manner to avoid any injury.

PM’s impact is improved when used alongside smart, connected worker solutions that allow for digital work instructions and remote collaboration to effectively and efficiently guide technicians. Additionally, by digitizing and automating maintenance notifications, organizations can improve communications, speed up maintenance procedures, and minimize machine downtime.

How to implement AM

Applying autonomous maintenance to everyday maintenance tasks can mitigate potential machine disasters. Organizations can take this even further by creating “smart” autonomous maintenance processes and implementing advanced connected worker solutions with AI-driven insights. This gives operators improved control over maintenence process and expert guidence through a searchable asset hierarchy, maintenance history, and troubleshooting database.

The seven steps of effective AM implementation:

  • Boost operator expertise: It’s important to train operators on the machines themselves and how to perform maintenance tasks. This type of training can be made more effective through AI-based insights that integrate skills management into the flow of work and identify workforce development opportunities for upskilling and reskilling.
  • Conduct initial cleaning, inspection, and repairs: Operators should execute regular maintenance activities to avoid unplanned downtime. Furthermore, with connected worker solutions, operators can use mobile devices to digitally track and manage issues and activities as well as automate maintenance notifications further reducing overall downtime and avoiding unplanned downtime.
  • Eliminate causes of contamination: Routine cleaning and inspection minimize sources of contamination such as improper calibration and defective equipment. This alone can help prevent unexpected machine breakdowns. By building smart workflows into the autonomous maintenance process, manufacturers can schedule and assign standard work procedures (such as routine cleaning and calibration) digitally that have built-in work reporting for better visualization and auditing.
  • Define standards for cleaning, lubricating, and inspecting: Nailing down how to clean, lubricate, tighten and inspect, and how often to perform these upkeep duties, can help keep equipment in pristine condition. Smart digitization can standardize these practices across all manufacturing operations, giving organizations a global best practices standard to measure standard work adherence, clear defects more quickly, and improve auditability.
  • Perform inspection and monitoring: Operators who are trained on maintenance processes can carry out maintenance tasks independently and without error. With smart skills management and AI-enhanced workforce development, organizations can reduce training time and provide individualized guidance and support to workers when and where needed.
  • Standardize visual maintenance: Incorporate visual aids that help operators better understand equipment and labeling. For example, written procedures could contain a diagram showing how fluids should flow in a particular machine. Continuous learning and personalized insights via connected worker solutions are able to take this one step further and integrate things like instructional videos, interactive diagrams, and even remote experts into the flow of work to improve operational excellence and productivity.
  • Work towards continuous improvement: It’s imperative to strive for continuous improvement in maintaining machinery. Operators who are constantly learning and evolving are more productive and empowered with better decision-making capabilities through actionable, AI-driven insights.

Learn more on how to implement autonomous maintenance and the seven steps involved, or get in touch with us for a personalized demo to see Augmentir’s Autonomous Maintenance solution in action.

See Augmentir in Action
Get in Touch for a Personalized Demo

 

Book A Demo

How to implement PM

According to Forbes, when implemented correctly, preventive maintenance ensures that upkeep is performed at a set time to prevent unexpected machine deficiencies. Smart, connected frontline worker solutions are able to improve preventative maintenance procedures through smart communication, scheduled notifications and improved collaboration.

Eight steps for implementing preventive maintenance:

  • Establish project scope: Gauge which machinery will be inspected and which maintenance tasks are needed to be done at specific intervals.
  • Pinpoint upkeep requirements: Set requirements for which tasks are crucial for each piece of equipment. Tasks could vary from lubrication and calibration to inspections and part replacements.
  • Create maintenance schedule: Create a set schedule for carrying out PM tasks that’s based on equipment requirements, production schedules, and planned downtime.
  • Allocate worker responsibilities: Assign which tasks each maintenance worker is expected to fulfill.
  • Provide necessary resources: Give staff the proper tools, equipment, and supplies to execute PM tasks (e.g., lubricants, replacement parts, testing equipment, etc.).
  • Define metrics: Establish metrics for gauging the efficiency of PM (e.g., downtime, equipment reliability, maintenance costs, etc.).
  • Create training programs: Hands-on training and how-to instructions can help maintenance workers better understand how to perform upkeep tasks.
  • Monitor performance and adjust: Measure how well your PM efforts are doing and revise if necessary. This may mean updating procedures, adjusting maintenance schedules, or creating more training opportunities.

All of these steps are able to be standardized and optimized through connected worker solutions. Augmentir’s suite of connected worker tools delivers in-line training and support at the point of work, provides a searchable database to allow workers access to knowledge when and where needed, gives workers individualized guidance and support, connects teams for better collaboration, and more. This approach helps standardize and optimize maintenance processes and notifications as well as training, offering a better, more efficient adoption process for both frontline workers and management from start to finish, and giving everyone the proper tools for successful manufacturing operations.

 

If you are interested in learning for yourself why companies are choosing Augmentir to help digitize and optimize their autonomous and preventive maintenance programs – reach out to book a demo.

 

See Augmentir in Action
Get in Touch for a Personalized Demo

 

Book A Demo