Empower your workforce with real-time, on-the-job performance support. Learn how Augmentir delivers AI-powered tools to boost productivity, reduce errors, and improve training efficiency.
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What Is Performance Support?
Performance support refers to tools and systems that deliver real-time, on-the-job guidance—helping workers complete tasks more efficiently and accurately. Unlike traditional training, which relies on employees retaining information for future use, performance support provides just-in-time knowledge exactly when and where it’s needed.
This approach addresses a critical challenge: information retention. According to a recent study by the Learning Guild, employees forget an average of 50% of classroom training within an hour. That figure rises to 70% within 24 hours, and up to 90% of the content is lost after just one week.
In contrast, delivering assistance and support at the moment of need, organizations can incorporate more learning processes into the everyday workday of frontline workers—essentially bridging the gap between knowing and doing. This “active learning” aligns with the Pyramid of Learning visual model that illustrates the different stages of learning and their relative effectiveness.
By delivering timely assistance at the moment of need, performance support closes the gap between learning and doing—boosting productivity, reducing errors, and increasing employee confidence.
Why Performance Support Matters
In today’s fast-paced world, businesses can’t afford downtime or mistakes due to forgotten procedures or unclear processes. That’s where performance support shines:
Reduces training time by enabling learning in the flow of work
Minimizes human error with guided workflows and checklists
Improves productivity with instant access to instructions, diagrams, or expert assistance
Boosts employee confidence and retention by removing the fear of making mistakes
Adapts to changing processes without retraining entire teams
Types of Performance Support Tools
Modern performance support systems come in a variety of forms:
1. Digital Work Instructions
Digital work instructions and step-by-step guides delivered on tablets, smartphones, or AR-enabled wearables that ensure workers follow best practices.
2. Smart Forms and Checklists
Interactive smart forms and checklists that adapt based on context, role, or equipment—reducing the risk of skipped steps or safety violations.
3. Knowledge Bases & Microlearning
Searchable libraries with short how-to videos, job aids, and FAQs, accessible at any moment of need.
4. AI-Based Guidance
Context-aware suggestions powered by AI that anticipate the user’s next move and offer proactive support.
Benefits of a Performance Support System
Implementing a performance support platform leads to measurable improvements:
Faster onboarding: New employees become productive in days, not weeks. In one example, a global packaging company reduced onboarding time by 72% using connected worker technology
Improved operational efficiency: Real-time support eliminates bottlenecks
Error reduction: Guided execution ensures compliance and safety
Continuous improvement: Insights from usage data help refine SOPs and training
Performance Support with Augmentir
Augmentir is the only AI-powered connected worker platform that delivers personalized, real-time performance support at scale.
How Augmentir Enhances Performance Support
Smart Digital Workflows: Augmentir allows you to create and deploy intelligent digital work instructions that adapt based on worker proficiency, context, and task complexity.
AI-Based Recommendations: Unlike static systems, Augmentir uses artificial intelligence to optimize each user’s experience—delivering dynamic guidance and identifying where additional support is needed.
Integrated Collaboration: Augmentir’s built-in manufacturing collaboration software tools connect frontline workers with subject matter experts instantly—ensuring issues are resolved in real time.
Personalized Learning in the Flow of Work: Using workforce data, Augmentir delivers workflow learning—targeted microlearning and upskilling opportunities during task execution—accelerating growth and minimizing disruption.
Connected Insights for Continuous Improvement: Data captured during task execution feeds into dashboards and analytics, helping you identify performance gaps, improve SOPs, and drive operational excellence.
Augmentir in Action
Manufacturers and industrial companies across the globe trust Augmentir to:
Cut training time by up to 60%
Reduce errors and rework by 40%
Increase first-time quality and throughput
Drive continuous workforce improvement with AI-driven insights
Implementing a robust performance support system isn’t just about efficiency—it’s about creating a culture of empowerment and agility. Workers feel supported, supervisors gain visibility, and businesses stay competitive.
Schedule a demo today to learn how Augmentir can elevate your performance support strategy.
AI and connected worker technology is helping frontline managers combat employee burnout and improve engagement and retention.
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Industrial work comes with an immense amount of stress. Without providing the worker with the right level of support, this stress can lead to increased errors, poor work performance, and eventually, employee burnout. Recently, Gallup reported that 76% of employees experience some form of workplace burnout. This not only affects performance and productivity but much more, including engagement and employee retention.
To offset employee burnout, managers should aim to:
Reduce employee stress
Remove roadblocks ensuring their workers have the proper tools to complete their tasks
Ensure workers are a good match skill-wise for the work they are doing
Give workers a say in how the work is completed
Empower workers to believe that the work they are doing is valued and important
In a 2022 Gallup poll, 79% of employees responded as not being engaged at work, this same poll found that most employees don’t find their work meaningful and do not feel hopeful about their careers.
When supporting workers and battling workplace burnout, there is no “one size fits all” answer, and many organizations are realizing that taking the same approach for “desk workers” does not account for the many and uniquely different needs demanded by frontline or “deskless” workers. Managers must keep in mind these needs when combating and detecting burnout and boosting employee engagement in manufacturing.
Artificial Intelligence (AI) and machine learning-based technology combined with a worker-centric approach can help tremendously in this respect, accounting for the human element in industrial operations while still taking advantage of innovations.
Using AI to Enhance Worker Experience and Reduce Burnout
By utilizing the capabilities of connected worker platforms and AI, companies can take a proactive approach to reducing stress and preventing employee burnout.
The meteoric rise of AI tools like ChatGPT and natural language processing has created a surge in interest in all things AI and while it’s not a cure-all, AI has the potential to be extremely effective in helping workers get access to the information and support they need while on the job, as well as predicting, detecting, and reducing workplace burnout. By taking highly granular connected worker data and using AI to filter out the unnecessary portions, industrial operations are able to not only improve tasks and productivity but better support and empower frontline workers. Organizations can use AI to engage employees by:
Creating communication touchpoints and streamlining communication
Pairing workers and tasks based on skill level
Suggesting training and certification opportunities for upskilling workers
Create feedback paths so employees have a say in how tasks are completed
To complement AI and software platforms, organizations can implement other tools such as wearable devices, mental health applications, and more to aid in engagement efforts. Finding the right balance and combination is key for knowledge exchange and conversation – making employees more engaged within the team.
The Human Element
It is important to take advantage of new technologies and implement them where needed, but technology by itself is not the answer. Finding a balance between technology integration and a worker-driven approach is key and it is paramount that the true needs of the workforce are not forgotten. Although AI and machine learning-based technology can help tremendously with detecting and reducing employee burnout, it has its limits and can only do so much. Technology cannot replace how workers feel and how they interact with management on a day-to-day basis. And at the end of the day, AI can only augment employees and should be used to empower them, never to replace them.
https://www.augmentir.com/wp-content/uploads/2023/03/human-side-of-ai.jpg6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2023-03-14 03:05:062025-05-27 16:10:51The Human Side of AI: Supporting Workers to Reduce Employee Burnout
Discover how a digital knowledge sharing platform helps frontline manufacturing teams reduce errors, preserve tribal knowledge, and improve productivity. Learn how Augmentir leads the way.
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In today’s fast-paced manufacturing environment, access to real-time knowledge can be the difference between downtime and delivery. A dedicated knowledge sharing platform designed for frontline operations ensures your teams are always informed, aligned, and equipped to solve problems efficiently.
Read this article to learn more about Knowledge Sharing in Manufacturing:
A Knowledge Sharing Platform in Manufacturing is a digital system designed to capture, manage, and distribute operational knowledge across frontline teams to ensure consistency, productivity, and continuous improvement. These platforms provide a centralized hub for essential information such as work instructions, standard operating procedures (SOPs), and troubleshooting guides, enabling consistent execution across shifts, teams, and locations.
Why Knowledge Sharing Matters in Manufacturing
Frontline workers are the backbone of production. Yet, many manufacturing organizations still rely on outdated methods—paper manuals, tribal knowledge, and siloed expertise—that lead to:
Inconsistent work execution
Longer training times
Increased errors and rework
Loss of critical expertise due to retirements or turnover
According to a study from the Manufacturing Institute, one-quarter of the manufacturing workforce is over 55 years old, and 97% of respondents reported that they fear losing tribal knowledge when these workers retire. With a digital knowledge sharing platform, you unlock the full potential of your workforce and preserve critical operational know-how.
Knowledge Sharing Platform Built for Frontline Workers
Unlike traditional enterprise platforms, a modern frontline knowledge sharing platform is:
Mobile-first: Accessible on tablets, phones, and wearable devices on the factory floor
User-friendly: Designed for non-desk workers with intuitive navigation and voice/image capture
Connected: Integrated with your existing MES, ERP, and quality systems
Real-time: Delivering updates, alerts, and best practices where and when they’re needed
Key Features of a Frontline Knowledge Sharing Platform
Standard Work Instructions
Digitize and manage standardized work procedures across all sites. Frontline workers can access step-by-step instructions with visuals, videos, and interactive guidance via mobile or wearable devices.
Ensure consistent execution
Reduce variation across shifts and teams
Support regulatory compliance with version-controlled documentation
Tribal Knowledge Capture
Enable seasoned workers to share their expertise directly from the floor using voice notes, images, and short video clips. All contributions are stored and searchable within the platform.
Preserve operational know-how from retiring workers
Promote peer-to-peer learning
Build a growing, living knowledge base
Continuous Feedback Loop
Workers can annotate procedures, suggest improvements, and flag issues in real-time, creating a two-way flow of information between the floor and management.
Accelerate process improvements
Increase worker engagement and ownership
Keep documentation accurate and up-to-date
Training & Onboarding Support
Embed microlearning and task-based training directly into workflows, allowing new hires to learn on the job with contextual guidance.
Shorten time-to-competency
Reduce dependency on in-person trainers
Improve retention through hands-on learning
Insights & Analytics
Track how knowledge is created, accessed, and applied. Understand which procedures are most used, where bottlenecks occur, and how workers are performing across roles and locations.
Identify training gaps and high-performing teams
Optimize procedures based on usage data
Support data-driven workforce development
Multi-Device Accessibility
The platform should support a range of devices—smartphones, tablets, AR glasses, or ruggedized terminals—ensuring knowledge is always available at the point of need.
Meet workers where they are
Enable flexibility across roles and environments
Support hands-free use in hazardous or hands-on scenarios
Secure, Scalable, and Cloud-Based
Built with enterprise-grade security, role-based access control, and scalability for global operations.
Protect sensitive operational data
Control who can view, edit, and share content
Scale across facilities and languages
Augmentir’s Connected Knowledge Platform for Frontline Operations
Augmentir delivers a purpose-built knowledge sharing platform for manufacturers, combining AI-powered insights with a modern, connected worker experience.
Here’s how Augmentir transforms knowledge for frontline teams:
AI-Driven Knowledge Curation
Augmentir automatically surfaces the most relevant content and best practices based on real-world usage and performance—ensuring workers always have access to the right knowledge at the right time.
Connected Worker Experience
Whether it’s accessing a digital work instruction, contributing a video tutorial, or flagging a problem, Augmentir makes frontline knowledge sharing seamless across devices and shifts.
Integrated Learning and Guidance
Train workers in the flow of work with embedded microlearning, just-in-time instructions, and step-by-step guided workflows—reducing training time and improving retention.
Operational Intelligence
Gain real-time visibility into how knowledge is used, where gaps exist, and which areas need improvement. Augmentir’s analytics help drive continuous improvement and workforce development.
Capture and Retain Tribal Knowledge
Turn your most experienced workers into knowledge contributors. Augmentir enables frontline employees to create and share insights from the floor—preserving critical know-how before it’s lost.
A knowledge sharing platform connects your people, processes, and data in real time—without disrupting your current operations. Empower your frontline workforce with a platform built for the way they work.
Schedule a live demo or contact us to learn how Augmentir’s AI-powered knowledge sharing platform can elevate your manufacturing operations.
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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Is your manufacturing operation still clinging to outdated paper-based processes? It’s time to face the facts: paper is holding you back. The effort spent managing paper trails, outdated Standard Operating Procedures (SOPs), and inconsistent training materials isn’t just inconvenient—it’s a direct drain on your productivity, efficiency, and bottom line.
Generative AI (GenAI) offers a transformative way to digitize content, automating the conversion of paper-based materials like SOPs, work instructions, and checklists into structured, editable digital formats. It can enhance content by improving clarity, integrating visuals, translating languages, and customizing workflows. This significantly reduces manual effort and accelerates transitions to cost-effective digital systems.
Read below to learn more about the challenges of content digitization, the potential benefits of going paperless, and how Augie, a Generative AI solution from Augmentir, is empowering manufacturing companies to accelerate their digital transformation.
A paperless shop floor in manufacturing offers numerous benefits, including enhanced efficiency by eliminating time-consuming manual paperwork and reducing errors. It provides real-time access to digital work instructions, improving accuracy and productivity for frontline workers. Digitization supports better compliance with safety and quality standards while enabling faster updates to workflows.
Additionally, going paperless reduces environmental impact by minimizing waste, aligns with sustainability goals, and fosters a connected, data-driven environment where insights from real-time data can drive continuous improvement and innovation.
Here are the top benefits of going paperless:
Accelerate employee onboarding: By digitizing onboarding and moving training into the flow of work, manufacturers can reduce new hire onboarding time by 82%.
Increase productivity: Digitizing manufacturing operations means no more manual, paper-based data collection or record-keeping. Workers have more time to run their equipment, execute shop floor tasks, and find solutions to problems.
Boost data accuracy: Humans are prone to making mistakes, but shop floor data capture and validation can help offset human error and improve accuracy.
Improved workforce management: Digital skills tracking and AI-based workforce analytics can help optimize production operations and maximize worker output.
Manage real-time operations: Human-machine interface systems eliminate the need for paper, files, and job tickets. This means that workers can analyze inventory and other data in real-time.
Save money, minimize waste: Although going paperless means that the cost of paper is eliminated, the savings extend beyond that. With greater productivity, operations in real-time, and improved production optimization, costs and waste can be reduced in many areas, aligning with corporate sustainability goals.
Challenges
Going paperless in manufacturing isn’t without challenges, and ignoring them can stall your progress.
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. Digitizing years’ worth of SOPs, work instructions, and checklists can feel overwhelming, but staying stuck in outdated systems costs more in the long run. Resistance from workers who are comfortable with paper-based processes can slow adoption, and if your digital tools aren’t intuitive, you risk alienating your team. Integration with existing systems is no small task, and if you’re not prioritizing data security, you’re leaving your operation vulnerable. Overcoming these hurdles is essential to stay competitive.
This is where Generative AI and Augie can provide transformational value.
Generative AI 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.
Your Paperless Shop Floor with Augie
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.
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 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.
With Augie, you can move past the inefficiencies of paper-based frontline work. Augie transforms your paper-based workflows into dynamic digital tools in just days, streamlining processes, reducing errors, and equipping your workforce to excel in today’s fast-paced environment.
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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
Digitizing isn’t just an upgrade—it’s a step toward smarter, more competitive operations. Augie optimizes content for frontline workers, provides real-time feedback, and eliminates barriers like language gaps or compliance issues. Paper simply can’t keep up with the actionable insights and adaptability that Augie offers.
Drive Manufacturing Efficiency with a Paperless Shop Floor
Augie revolutionizes the connected worker journey by offering a robust suite of AI tools that grow alongside organizational needs. It begins by transforming static, paper-based processes into dynamic, interactive workflows, enhancing accessibility and efficiency for frontline workers. As operations become digitally connected, Augie uses real-time data to identify inefficiencies, optimize workflows, and drive continuous improvement.
The Augie Industrial Gen AI Suite transforms every stage of the Connected Worker Journey.
With its seamless integration capabilities, Augie creates a scalable ecosystem, enabling innovation and adaptability. This comprehensive approach empowers organizations to modernize operations and build a foundation for sustained success and growth.
If you’re ready to modernize and future-proof your operations, Augie is here to help you take the leap into a truly paperless shop floor. If you’re serious about building a resilient, efficient operation, it’s time to stop making excuses and start taking action. Augie isn’t just a tool—it’s the future of manufacturing. Step into a paperless shop floor and see the difference for yourself.
https://www.augmentir.com/wp-content/uploads/2025/01/paperless-shop-floor-with-augie-1.webp12602400Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2025-01-19 20:41:282025-05-22 11:58:52Step into a Paperless Shop Floor with Augie
Learn how connected worker technology can help you standardize and digitize layered process audits for improved accuracy and better quality results.
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Digitized Layered Process Audits (LPAs) are important in manufacturing for establishing and enhancing process standardization, quality management, multi-level workforce engagement, risk mitigation, and quality standards compliance. The primary function of a Layered Process Audit is to focus on observing and validating how products are made to ensure process and product quality. This effectively protects manufacturers and frontline manufacturing personnel from defects and process issues before they can do any damage.
Many crucial manufacturing processes are still carried out using outdated pen-and-paper methods; and as the industry continues to evolve, digitization is essential to remain competitive and maintain proper quality and safety standards. Layered Process Audits are no exception, with digitized layered process audits now a necessity, rather than a luxury, for organizations looking to keep pace, elevate their audit processes, and meet the demands of the evolving industry.
Learn more about how to streamline LPAs with connected worker technology, implement digital LPAs, and the benefits of AI-powered analytics for digitized LPAs and overall quality management excellence in manufacturing below.
Connected worker platforms allow manufacturers to replace paper-based audit forms (like a layered process audit) with digital checklists that can be accessed and completed on mobile devices, allowing for:
Standardized audit formats and best practices across audit layers
Real-time data collection and improved audit tracking
Mobile access to information and knowledge including relevant documents, procedures, and historical data
Automated audit scheduling and notifications for consistent audit frequency across layers and reduced administrative burden
Real-time issue reporting and escalation for faster response and issue resolution
Improved data analytics and reporting to generate and apply insights as well as identify recurring issues and root causes
Overall system integrations with things like ERP, MES, and CMMS
These abilities offer a significant boost to manufacturers in terms of operational efficiency, risk mitigation, workforce development, and cost reduction.
Implementing Digital Layered Process Audits
Manufacturers can digitize LPAs and streamline their quality management processes through AI-powered connected worker technologies, improving data quality and driving faster, more effective quality improvements across the organization.
Implementing digital Layered Process Audits (LPAs) involves several steps, from selecting the right platform to engaging the team and ensuring proper integration with existing systems. Below is a step-by-step guide to implementing digital LPAs effectively:
1. Choose the right Digital LPA Platform
Research and select a digital LPA platform that meets your organization’s needs. Consider factors like:
Ease of use (especially for mobile devices)
Customizability (to fit your audit checklist and process requirements)
Integration with existing systems (e.g., ERP, quality management systems)
Reporting and analytics capabilities
Scalability for future needs
2. Develop and Digitize Audit Checklists
Standardize Audit Checklists: Create or review the audit checklists for each layer of the audit process. Ensure they are aligned with your goals, operational requirements, and industry standards (e.g., ISO, IATF).
Digitize the Checklists: Input these checklists into the digital platform. Ensure that they are tailored to different levels of the audit process, from shop floor employees to higher-level management.
Customize Alerts and Criteria: Set up criteria for success/failure and alerts for non-conformance. This can include conditional triggers where a failed audit automatically prompts corrective actions.
3. Integrate with Other Systems
Link to Quality Management Systems (QMS): Integrate the LPA platform with your existing QMS, ERP, or other relevant systems to streamline data sharing and analysis.
Automate Corrective Action Processes: Ensure that non-conformance findings in the audit automatically trigger corrective action workflows, and link them to task management or follow-up procedures.
4. Monitor, Analyze, and Improve
Track Real-time Results: Use the platform’s dashboards and analytics features to monitor performance metrics, such as audit completion rates, non-conformance trends, and the time taken to close corrective actions.
Conduct Regular Reviews: Hold periodic review meetings with the audit team and management to discuss audit findings and trends. Use this information to drive continuous improvement in processes.
Make Adjustments: Based on the insights from the audits, adjust the audit checklists, procedures, and corrective action plans as needed.
5. Foster a Culture of Continuous Improvement
Encourage Engagement: Foster a culture where employees see the value in LPAs and actively participate in the process. Offer incentives or recognition for high levels of engagement or process improvements resulting from audits.
Regularly Update the System: Keep the digital platform and audit processes updated to reflect changes in standards, regulations, or internal processes.
Leverage Advanced Analytics: Over time, use advanced analytics and machine learning (if available) to predict potential non-conformance areas and further streamline corrective actions.
By following these steps, you can effectively implement a digital Layered Process Audit system that enhances visibility, accountability, and process control across your organization.
Driving Continuous Quality Improvement with Digitized LPAs
Excellence in quality management drives success in manufacturing. Digitizing and updating old processes with AI, connected worker platforms, and even simple digital layered process audit software allows manufacturing organizations to better identify and prevent defects at their source and protect against rework, customer complaints, costly product recalls, and reputational damage.
Recent innovations in AI technology and applications caused an explosion of growth all across the world and in various industries. Manufacturing is uniquely situated to adopt these technologies for massive growth. One valuable use case is the use of AI to optimize quality management, specifically to optimize audit processes like LPAs for drastically improved results and insights that simply weren’t possible previously.
AI analytics combined with connected worker technologies digitize and streamline layered process audits allowing manufacturers to capitalize on shop floor data data capture for:
Trend analysis across different audit layers, departments, and locations
Automated population of audit forms with relevant data
Application of cobots, generative AI assistants, or AI copilot technologies to support auditors and workers alike.
But this does not stop there, according to a study by McKinsey & Company, companies that prioritize quality management achieve higher levels of employee engagement. Engaged employees are more likely to be committed to producing high-quality products, resulting in increased productivity and customer satisfaction. The addition of AI to capitalize on connected worker data and feedback to generate insights, support enhanced decision-making, and create better processes offers manufacturers a path forward into the future with a better-equipped and supported frontline workforce.
Interested in learning more?
If you’d like to learn more about how Augmentir streamlines and optimizes quality management processes like digital layered process audits and more, schedule a demo with one of our produce experts.
https://www.augmentir.com/wp-content/uploads/2024/10/digital-layered-process-audits.webp12602400Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2024-09-28 15:28:512025-05-22 11:57:50How to Digitize Layered Process Audits with Connected Worker Technology
Learn how manufacturers combat the manufacturing skilled labor shortage and close skills gaps with an Augmented Connected Workforce (ACWF).
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An Augmented Connected Workforce (ACWF) offers manufacturing and other industrial organizations a powerful solution to combat the ever-worsening skilled labor shortage and skills gap. According to a report by Deloitte and the Manufacturing Institute, an estimated 2.1 million manufacturing jobs could go unfilled by 2030 and the cost of those missing jobs could potentially total $1 trillion in 2030 alone.
By integrating advanced technologies like artificial intelligence (AI), connected worker platforms, and other emerging solutions manufacturers can enhance the capabilities of their existing workforce and bridge skill gaps. Connected worker tools offer real-time monitoring of your frontline workforce, ensuring seamless operations. Moreover, connectivity enables remote collaboration, allowing experts to assist frontline workers from anywhere in the world. This interconnected ecosystem empowers workers with the tools they need to succeed and attracts new talent by showcasing a commitment to innovation and technology-driven growth.
Through an ACWF, manufacturers can effectively combat the manufacturing skilled labor shortage and close the skills gap while driving productivity, innovation, and remaining competitive. Read more about ACWF in manufacturing below:
A critical element of transitioning from a traditional workforce to an Augmented Connected Workforce (ACWF) is implementing and adopting new technologies and processes. Here are a few steps that can help with the adoption of ACWF technologies and smooth transitions in industrial settings:
Step 1: Assess Current Processes – Organizations must understand existing workflows and identify areas where AI, connected worker platforms, and other ACWF technology can replace paper-based and manual processes to enhance efficiency and productivity.
Step 2: Invest in Technology – Procure AI-driven analytics platforms, mobile technology, and wearable technology to enable real-time data collection and remote collaboration.
Step 3: Training and Onboarding – Provide comprehensive training programs to familiarize workers with new technologies and workflows. Emphasize the importance of safety protocols and data privacy.
Step 4: Pilot Programs – Start with small-scale pilot programs to test the effectiveness of the implemented technologies in real-world manufacturing environments. Target high-value use cases that can benefit from a transition from paper to digital.
Step 5: Continuous Improvement – Gather feedback from workers and supervisors during pilot programs and adapt implementation initiatives based on their input. Continuously optimize processes and technologies for maximum effectiveness.
By following these steps, manufacturers can smooth the transition from a traditional manufacturing workforce to an ACWF, empowering their frontline workers with improved capabilities, skills, and overall operational excellence.
Supporting Learning in the Flow of Work
Augmented Connected Workforce (ACWF) technologies allow for increased frontline support and for new processes around learning and training to strategically upskill and reskill, reduce time to competency for new workers, and to combat the skilled labor shortage in manufacturing and more. Connected worker tools, such as wearable devices and IoT sensors, enable real-time monitoring of worker performance and environmental conditions, ensuring safety and efficiency on the factory floor.
An ACWF also allows for improved workflow learning capabilities giving frontline workers access to expert guidance, remote assistance and collaboration, microlearning, and other learning in the flow of work options regardless of the worker’s location.
ACWF tools further enhance frontline activities through:
Digital work instructions and guidance: Smart, connected worker platforms provide digital work instructions, procedures, and visual guidance easily accessible to workers on mobile devices.
Digital mentors and training: Some ACWFs incorporate “digital mentors” – GenAI-powered industrial assistants that can provide step-by-step guidance to workers, especially new hires.
Knowledge capture and sharing: Connected frontline worker applications serve as knowledge sharing platforms, capturing data and insights from frontline workers, which can then be analyzed by AI software and used to improve processes, update work instructions, and share knowledge across the organization
Performance monitoring and feedback: ACWF solutions provide visibility into worker performance, allowing managers to identify areas where additional training or support is needed.
In summary, ACWF initiatives empower frontline workers with the digital tools, knowledge, and support they need to learn and improve their skills directly within their daily workflows, rather than relying solely on formal training programs. This helps close skills gaps and drive continuous improvement.
Future-proofing Manufacturing Operations with an ACWF
Adopting an Augmented Connected Workforce (ACWF) approach centered around augmenting frontline workers with mobile technology, immersive training, collaborative decision-making, and continuous improvement, allows manufacturers to future-proof their operations and gain a sustainable competitive advantage. This concept empowers employees with powerful tools that augment and enhance their capabilities, productivity, and overall business processes by accessing critical information and fostering collaboration
AI-powered software can analyze vast amounts of data to optimize production processes and predict workforce development needs. At the same time, connected frontline worker solutions enable the integration of mobile and wearable technologies and provide real-time data insights, aiding in optimizing factory operations and adapting to evolving industry trends.
For an Augmented Connected Workforce, integrating AI and connected worker technologies serves as a vital strategy for manufacturers navigating the skilled labor crisis. Augmentir encourages organizations to embrace ACWF transformations and expedites adoption through a comprehensive connected worker platform leveraging the combined benefits of connected worker and AI technologies.
With Augmentir, frontline workers can access critical information, real-time data and insights, and expert advice and guidance all in the flow of work preventing lost time and improving both efficiency and productivity. Schedule a live demo to learn more about how an Augmented Connected Workforce future-proofs manufacturing operations and enhances frontline activities.
https://www.augmentir.com/wp-content/uploads/2024/06/augmented-connected-workforce-acwf-manufacturing.webp6301200Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2024-04-03 16:14:362025-05-22 11:56:03How to Combat the Manufacturing Skills Gap with an Augmented Connected Workforce (ACWF)
Discover smarter issue management strategies to boost efficiency, reduce downtime, and streamline industrial operations with intelligent, proactive solutions.
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Issue management in industrial settings is the structured process of identifying, documenting, and resolving operational problems to maintain efficiency, safety, and quality. Connected worker tools play a transformative role by enabling frontline teams to report and address issues in real time, ensuring faster resolution and continuous improvement.
Read our article below to learn more about Issue Management in Manufacturing:
What is Issue Management in Industrial Operations?
Issue management in industrial settings is the structured process of identifying, documenting, and resolving operational problems to maintain efficiency, safety, and quality. Connected worker tools play a transformative role by enabling frontline teams to report and address issues in real time, ensuring faster resolution and continuous improvement.
Issue management refers to the process of identifying, tracking, and resolving problems that impact daily operations. These issues can include equipment malfunctions, quality deviations, safety incidents, process bottlenecks, and supply chain disruptions. In complex industrial environments—such as manufacturing plants, energy facilities, and logistics hubs—even small issues can ripple through the operation, causing costly downtime and rework.
Effective issue management is essential for maintaining operational efficiency, consistency, and safety. It ensures problems are not only addressed quickly but also documented and analyzed for future prevention.
Issue management is also a fundamental component of Lean manufacturing. Within a Lean framework, addressing issues swiftly and at the source is critical for minimizing waste (muda), improving process flow, and enabling continuous improvement (Kaizen). Effective issue management supports Lean principles, originally identified by Taiichi Oohno, by promoting standardization, visual control, and empowering frontline workers to contribute to quality and productivity improvements.
Common Challenges in Issue Management
Organizations often face several challenges when managing operational issues:
Manual Processes: Paper-based or spreadsheet systems slow down response times and increase the risk of human error.
Lack of Visibility: Disconnected systems hinder real-time tracking, making it difficult to prioritize and resolve problems effectively.
Poor Communication: Important details are lost during shift handover or between departments, especially in 24/7 operations.
Delayed Resolution: Without a standardized, traceable process, recurring issues continue to disrupt performance and morale.
These challenges lead to longer downtime, inconsistent quality, and reduced trust in issue reporting systems.
Pro Tip
Using connected worker solutions can help improve issue management with improved visibility and reporting, mobile reporting and issue tracking, workflow automation, and collaboration tools.
Digital Solutions to Address Issue Management
Modern industrial operations require more than reactive problem-solving. They need connected, real-time, intelligent tools that help prevent issues before they escalate. Traditional methods simply can’t keep up with the speed and complexity of today’s operations, where problems can rapidly multiply and impact cost, quality, and customer satisfaction.
A digital solution helps organizations move from reactive issue handling to a more predictive, proactive, and data-informed strategy. These systems not only streamline how issues are reported and resolved but also enable greater transparency and continuous improvement.
Types of Digital Solutions for Issue Management:
Connected Worker Tools
Combine digital guidance, remote collaboration, performance support, and real-time feedback into one platform. These tools empower frontline workers with the right information at the right time, enhance decision-making, and drive faster issue resolution.
Mobile Reporting Tools
Allow frontline workers to report issues directly from their mobile devices with photos, voice notes, and structured forms. Collaborative Platforms: Facilitate real-time communication between teams to ensure quick action and alignment.
Workflow Automation
Automatically assign tasks, trigger alerts, and ensure accountability across teams and shifts.
Integrated Dashboards
Provide visibility into issue trends, resolution time, and performance metrics.
AI and Analytics Tools
Analyze data to identify recurring issues, uncover root causes, and recommend preventive actions.
Training and Knowledge Management Systems
Tie issue management to employee training, so workers can learn from past incidents and avoid repeating mistakes.
With a modern digital solution, organizations can:
Capture and categorize issues in real-time from any device
Assign tasks with clear accountability and deadlines
Track resolution progress across shifts and teams
Surface trends that inform strategic improvements
Enhance collaboration and cross-functional learning
Best Practices for Issue Management in Manufacturing
Implementing effective issue management requires more than just tools—it demands consistent best practices that support a culture of accountability and improvement. Here are key practices to follow:
Standardize Reporting: Ensure all employees use the same process and language to report issues. Digital templates and forms help create consistency.
Empower Frontline Workers: Make it easy for anyone on the floor to log an issue quickly, without bureaucratic roadblocks.
Respond in Real Time: Establish clear protocols for triaging and escalating issues based on severity and impact.
Integrate with Existing Systems: Sync issue tracking with maintenance, quality, and training systems to provide full visibility and context.
Track and Analyze Trends: Use dashboards and analytics to identify recurring problems and opportunities for improvement.
Close the Loop: Make sure every issue leads to a documented resolution, including root cause analysis and preventive actions.
Promote Continuous Improvement: Use issue data to drive Kaizen events, lean manufacturing projects, or training enhancements.
How Augmentir Enhances Issue Management
Augmentir’s connected worker platform transforms how frontline teams identify and solve problems. By embedding AI and collaboration tools into everyday workflows, Augmentir ensures that no issue goes unnoticed—or unresolved.
Key capabilities include:
Digital Issue Capture: Workers can report issues with rich detail (text, photos, voice), improving clarity and response.
Real-Time Notifications: Alerts and escalations ensure the right people are engaged immediately.
AI-Powered Root Cause Analysis: Augmentir continuously learns from your operations, suggesting root causes and identifying patterns.
Connected Workflows: Seamlessly link issues to related work instructions, safety protocols, and training content.
Operational Insights: Dashboards visualize issue frequency, impact, and resolution efficiency across teams, sites, or business units.
Augmentir goes beyond digital forms and basic tracking—it provides an intelligent, end-to-end issue management system. With built-in AI, collaboration tools, and analytics, Augmentir equips your workforce with everything needed to detect, manage, and eliminate operational problems at their source.
Whether you’re operating a multi-site manufacturing network, running a high-stakes field service team, or managing supply chain logistics, Augmentir delivers the tools to keep your operations resilient and responsive.
Discover key strategies to boost production efficiency in manufacturing—maximize output, cut waste, and improve operations with smart, practical solutions.
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In today’s competitive industrial landscape, production efficiency in manufacturing is a critical factor that directly impacts profitability, customer satisfaction, and long-term business success. To achieve production efficiency, the actual output must match the optimal standard output, which involves minimizing waste, reducing downtime, optimizing labor, and ensuring consistent quality at every step of the manufacturing process.
Introduction to Production Efficiency
Production efficiency refers to the ability of a manufacturing process to produce the maximum output with the given resources, while minimizing waste and reducing costs. It is a key concept in economics and operational analysis, essential for businesses to remain competitive in the market. Achieving production efficiency involves optimizing processes, reducing waste, and improving productivity to achieve higher profitability and competitiveness. By focusing on improving production efficiency, manufacturers can increase their production capacity, reduce costs, and enhance product quality. This, in turn, leads to increased customer satisfaction and loyalty, as high-quality products are delivered consistently and on time.
What is Production Efficiency in Manufacturing?
Production efficiency refers to the ability of a manufacturing operation to produce goods using the least amount of resources—time, materials, and labor—without compromising on quality. An efficient production line runs smoothly, minimizes bottlenecks, and ensures equipment and workforce are fully utilized. To measure production efficiency, metrics such as Overall Equipment Effectiveness (OEE), cycle time, yield rates, and labor productivity are used.
Pro Tip
Using digital tools, AI-powered analytics, and connected worker platforms are revolutionizing how factories operate. These technologies provide visibility into operations, uncover hidden inefficiencies, and support agile decision-making.
Why is Production Efficiency Important?
In manufacturing, even small inefficiencies can lead to significant cost overruns, missed deadlines, and quality issues. Improving production efficiency is essential for maximizing output while minimizing input—helping manufacturers stay competitive, agile, and profitable in an ever-evolving market. Manufacturing efficiency, on the other hand, focuses specifically on optimizing the effectiveness of manufacturing processes, workforce deployment, and overall productivity on the shop floor. Efficient production processes enable manufacturers to do more with less, which not only boosts the bottom line but also enhances the overall customer experience.
Here are some of the key benefits:
Lower Operational Costs
By reducing machine downtime, optimizing labor, and minimizing material waste, companies can optimize processes to significantly cut overhead costs and improve profitability.
Reduced Waste and Rework
Quality control ensures that products are made right the first time, decreasing scrap rates and minimizing costly rework caused by defects or human error.
Shorter Lead Times
Streamlined workflows and fewer production delays, coordinated through efficient production schedules, mean faster turnaround times, allowing manufacturers to fulfill orders more quickly and meet tight delivery schedules.
Better Resource Utilization
Whether it’s labor, machinery, or raw materials, efficient production ensures every resource is used to its full potential throughout the entire production cycle—maximizing value and reducing idle time.
Higher Customer Satisfaction
Consistently delivering high-quality products on time builds trust with customers and strengthens relationships, leading to repeat business and positive brand reputation. Manufacturers improve efficiency by leveraging modern technologies and real-time data analytics, which helps streamline processes, reduce downtime, and enhance productivity.
Greater Competitiveness in the Market
Manufacturers that improve efficiency can offer better prices, respond faster to market changes, and innovate more effectively—gaining a clear edge over less agile competitors.
Ultimately, production efficiency is not just about internal gains—it’s a strategic advantage that drives growth, scalability, and long-term success.
Key Strategies to Improve Production Efficiency
Here are some proven strategies to improve production efficiency:
1. Implement Lean Manufacturing Principles to Drive Continuous Improvement
Lean manufacturing methodologies focus on improving efficiency by eliminating waste (or “muda”) from every aspect of the production process. Tools such as 5S Audits, Kaizen, and value stream mapping help identify inefficiencies and areas for continuous improvement.
2. Invest in Autonomous Maintenance and TPM
Encouraging operators to handle basic maintenance tasks—such as Clean, Inspect, Lubricate (CIL)—as part of an Autonomous Maintenance and Total Productive Maintenance (TPM) strategy minimizes equipment downtime, improves machine efficiency, and ensures machines run at peak performance.
3. Leverage Digital Work Instructions and Connected Worker Tools
Modern digital approaches like digitizing standard operating procedures (SOPs) and adopting connected worker tools helps ensure consistency, reduce errors, and make it easier to train workers by providing accurate data.
In a recent survey conducted by LNS Research, more than 70% of the most profitable manufacturers are currently utilizing in Future of Industrial Work (FOIW) initiatives and connected worker technology, with the vast majority of them seeing meaningful progress and delivered corporate value through these workforce initiatives. Connected Worker platforms like Augmentir enable manufacturers to create AI-powered workflows that guide frontline workers through each task efficiently and accurately.
3. Use Real-Time Data and Analytics to Track Key Performance Indicators
Data-driven decision-making is critical for efficiency. Historical data can provide insights into the maximum output achieved by a facility under full capacity, which can help in defining standard outputs accurately. Real-time monitoring of machine performance, operator productivity, and process quality helps identify issues quickly and supports predictive maintenance strategies.
4. Streamline Workforce Management
Matching the right tasks to the right workers based on skills, experience, and availability reduces errors and idle time for any manufacturing company. Smart workforce tools can track training, performance, and certification to ensure optimal labor allocation.
Critical Components of Production Efficiency
Equipment Efficiency
Equipment efficiency is a critical component of production efficiency, as it directly impacts the overall productivity and effectiveness of the manufacturing process. Equipment efficiency refers to the ability of machinery and equipment to operate at optimal levels, with minimal downtime and maintenance. To achieve equipment efficiency, manufacturers can implement regular maintenance schedules, invest in modern and efficient equipment, and provide training to operators to ensure they are using the equipment correctly. By improving equipment efficiency, manufacturers can reduce waste, minimize downtime, and increase overall production efficiency. This not only enhances the reliability of the production process but also ensures that machinery operates at peak performance, contributing to higher output and better product quality.
Capacity Utilization
Capacity utilization is a key performance indicator (KPI) that measures the extent to which a manufacturing facility is using its available capacity to produce goods. It is calculated by dividing the actual output by the maximum potential output and is expressed as a percentage. Capacity utilization is essential for production efficiency, as it helps manufacturers identify areas of inefficiency and optimize their production processes. By improving capacity utilization, manufacturers can increase their production capacity, reduce costs, and improve product quality. High capacity utilization indicates that a manufacturing facility is effectively using its resources, leading to more efficient operations and better alignment with market demand.
Inventory Management
Inventory management is a critical component of production efficiency, as it directly impacts the availability of raw materials and finished goods. Effective inventory management involves managing the flow of goods, services, and related information from raw materials to end customers. By implementing efficient inventory management systems, manufacturers can reduce waste, minimize stockouts, and improve overall production efficiency. Inventory management involves tracking inventory levels, managing supply chains, and optimizing inventory turnover to ensure that the right products are available at the right time. This not only helps in meeting customer demand promptly but also reduces the costs associated with excess inventory and stockouts, contributing to a more streamlined and efficient production process.
Workforce Management
Workforce management (WFM) is a critical component of production efficiency because it directly impacts how well human resources are aligned with operational goals. Here are the key reasons why:
Optimal Staffing: WFM ensures the right number of workers with the right skills are available when needed, reducing overstaffing (which increases costs) and understaffing (which leads to delays or quality issues).
Productivity Monitoring: Through tracking attendance, breaks, and output, WFM helps identify performance gaps and opportunities to improve workflow or training.
Cost Control: Efficient labor scheduling and time management reduce overtime expenses, idle time, and unplanned labor costs.
Compliance and Risk Management: Proper WFM systems help companies stay compliant with labor laws, union rules, and safety standards, reducing legal and financial risk.
Employee Engagement: Transparent scheduling, fair workload distribution, and career development through performance data can boost morale and reduce turnover, which supports consistent productivity.
Forecasting and Planning: WFM tools use historical data to predict future labor needs based on demand, helping operations run smoothly during peak and off-peak periods.
Connected worker platforms are a vital solution for workforce management because they digitize and streamline the way organizations engage with their frontline employees, enabling real-time communication, task coordination, and data capture. These platforms empower workers by providing instant access to schedules, training, and support tools, while giving managers visibility into performance and resource needs. By collecting operational data at the source, they support better forecasting, faster decision-making, and improved compliance with safety and regulatory standards. Ultimately, they enhance agility, reduce inefficiencies, and ensure that the workforce is aligned with evolving production demands.
Improving Production Efficiency with Augmentir
Modern manufacturing is increasingly driven by digital transformation. Tools like Industrial IoT (IIoT), AI-powered analytics, and connected worker platforms are revolutionizing how factories operate. These technologies provide visibility into operations, uncover hidden inefficiencies, and support agile decision-making.
Connected Worker Technology is transforming the way manufacturers approach production efficiency by bridging the gap between frontline workers and digital operations. These platforms equip workers with real-time access to information, interactive digital work instructions, and collaboration tools—right at the point of work. By digitizing tasks, capturing live performance data, and enabling guided workflows, connected worker solutions ensure that every job is done accurately, efficiently, and consistently.
With features like AI-driven insights, skills tracking, and remote expert support, Connected Worker platforms help manufacturers identify bottlenecks, reduce errors, and optimize workforce deployment. Tools such as Augmentir go a step further by personalizing guidance based on an individual’s skill level, automatically suggesting improvements, and helping identify opportunities for continuous training and upskilling. Ultimately, Connected Worker Technology empowers teams to work smarter, adapt faster, and drive sustainable gains in production efficiency.
Augmentir serves as a digital frontline operating system for your lean strategy, and helps improve production efficiency. With Augmentir, you can digitize, manage, and optimize all aspects of your frontline operation:
https://www.augmentir.com/wp-content/uploads/2025/05/production-efficiency-in-manufacturing.webp12602400Chris Kuntzhttps://www.augmentir.com/wp-content/uploads/2021/09/Augmentir_Logo_Sm-300x169.pngChris Kuntz2025-04-15 16:09:192025-05-17 03:10:52Production Efficiency in Manufacturing: Strategies for Maximizing Output and Reducing Waste
