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Unlock frontline workforce performance and improve safety and quality by removing 7 key barriers with Augmentir’s AI-powered Connected Worker Platform.

In a recent conversation with a manufacturing operations leader now focused on training, a familiar challenge emerged: pinpointing the true culprits behind frontline performance issues. Is it the process? The training? Or something deeper?

Rather than spinning in circles, we reframed the conversation with one simple, powerful question:

“What barriers exist that prevent good performance?”

frontline workforce performance in manufacturing

This shift in perspective uncovered a set of common – and deeply entrenched – challenges. But more importantly, it revealed how the right digital tools, like Augmentir’s Connected Worker Platform, can systematically remove these barriers to unlock new levels of efficiency, quality, and engagement.

1. Inconsistent or Outdated Work Instructions

“Operators don’t always have clear, current procedures. We rely on tribal knowledge too much.”

When frontline workers rely on word-of-mouth or outdated paper instructions, variability and errors become inevitable. Small deviations in procedure can accumulate into major quality issues or production inefficiencies.

The results? Incorrect assemblies, wasted materials, process delays, or even safety incidents. Over time, these inconsistencies create a culture of uncertainty, where each shift or team may interpret the “right way” differently — hurting overall operational performance.

How Augmentir Helps:

  • Smart Digital Workflows: Augmentir digitizes and standardizes work instructions, ensuring that every operator, on every shift, follows the most up-to-date procedures. Augmentir’s no-code authoring environment allows you to create, update, and deliver work instructions to users through any mobile device or wearable technology appropriate for the job.
  • Augie™ Generative AI Content Assistant: Quickly generate standard work procedures from Excel, Word, PDFs, images, or videos. Augie takes your existing content and generates digital smart forms, checklists, and digital work instructions.
  • AI-driven content recommendations: The platform continuously learns from real-time execution data, surfacing opportunities to update or improve workflows based on actual performance and feedback.

create digital safe work permit

2. Lack of Visibility into Workforce Capability

“We don’t always know who’s trained or qualified to do what. That slows us down or leads to errors.”

Without a clear view of skills and qualifications, managers are left guessing. As a result, unqualified workers may be assigned to critical tasks, increasing the risk of quality defects or compliance violations. Teams lose time shuffling responsibilities, and supervisors become hesitant to delegate.

This visibility gap also creates missed opportunities for upskilling and slows down workforce agility — a major issue in today’s high-turnover environments.

How Augmentir Helps:

  • Skills & Certification Tracking: Augmentir’s digital skills matrix and skills management capabilities give supervisors real-time visibility into who is qualified for each task.
  • Personalized Work Instructions: Smart work instructions deliver guidance and support matched to the needs of each worker, so that everyone can work at their personal best.
  • AI-Based Workforce Profiling: The system learns from task execution data to automatically update worker profiles, enabling smarter workforce planning and targeted upskilling.

3. Reactive Problem Solving

“We often operate in firefighting mode. By the time we detect a problem, it’s already costly.”

Manufacturing teams often find themselves reacting to quality issues, inefficiencies, or breakdowns after the damage is done. This “firefighting mode” leaves little time for structured problem solving and often results in compounding consequences — missed production targets, increased scrap or rework, unexpected downtime, or worse.

When frontline teams are stuck in reactive cycles, quality issues go undetected, potentially leading to customer complaints, warranty claims, or even costly product recalls. In high-risk environments, delayed detection can also result in safety incidents, regulatory violations, or compliance lapses. In short, reaction-mode doesn’t just waste time — it puts revenue, reputation, and workers at risk.

How Augmentir Helps:

  • Real-Time Operational Insights: Augmentir captures granular execution data across tasks, revealing trends and anomalies before they escalate.
  • AI-Powered Root Cause Analysis: The platform correlates performance data with variables like shift, equipment, and training gaps to surface underlying causes — proactively.
  • Industrial Collaboration Tools: Effectively collaborate and share information across your frontline teams. Augmentir provides manufacturing collaboration software to support context-based collaboration, connecting team members across shifts, plants, and languages.
  • Automated Alerts and Dashboards: Teams can receive real-time notifications and visualizations that help prioritize issues before they disrupt operations.

manufacturing collaboration software from augmentir for continuous improvement in manufacturing

4. Disconnected Systems and Information Silos

“Information lives in too many places — paper, spreadsheets, different apps — so we don’t see the full picture.”

When critical information is fragmented across departments and systems, decision-making becomes slow, misinformed, or reactive. Frontline teams waste time hunting down documents, while managers struggle to identify trends or take corrective action across shifts and sites.

This fragmentation contributes to process delays, miscommunication, redundant training efforts, and reduced responsiveness — all of which erode efficiency and customer satisfaction.

How Augmentir Helps:

  • Integrated, Single Pane of Glass Platform: Augmentir centralizes work instructions, training records, skills data, and performance analytics into a single platform.
  • Built-in Integrations: Seamless connections with MES, ERP, QMS, and LMS systems ensure that frontline and back-office teams stay aligned.

augmentir connected-worker platform single pane of glass for frontline operations

5. Low Engagement or Lack of Ownership

“Operators don’t always feel connected to the bigger picture. That impacts quality and efficiency.”

When workers feel like cogs in a machine — disconnected from purpose, feedback, or opportunities for growth — their performance suffers. Disengagement leads to lower productivity, reduced quality focus, and higher turnover, all of which directly impact the bottom line.

Without ownership and recognition, frontline teams are less likely to take initiative, escalate issues, or contribute ideas for improvement.

How Augmentir Helps:

  • Personalized Work Experiences: Augmentir tailors tasks and support to each worker’s skill level and role, helping them succeed and grow.
  • Feedback Loops and Microlearning: The platform makes it easy for workers to give feedback and receive targeted coaching, reinforcing a culture of continuous improvement.
  • Digital Recognition & Performance Insights: Operators can see their impact and progression over time, boosting engagement and accountability. This improves workforce performance throughout the employee lifecycle.

the connected worker lifecycle and continuous improvement in manufacturing

6. High Turnover and Training Burden

“We’re constantly onboarding and retraining. It’s hard to get people up to speed quickly.”

Frequent turnover and lengthy training cycles make it difficult to maintain consistent performance. Traditional training approaches often require pulling experienced workers off the floor, leading to productivity dips and training bottlenecks.

The consequences include long ramp-up times, repetitive errors from new hires, and overburdened veteran employees. Worse, training documentation often goes stale quickly, failing to reflect process changes or lessons learned.

How Augmentir Helps:

  • Accelerated Onboarding: Step-by-step guided workflows with embedded videos and support reduce time-to-competency.
  • On-the-Job Learning: Contextual guidance within tasks enables learning in the flow of work, minimizing downtime and increasing retention.
  • Training Content Versioning: Built-in tools ensure training materials evolve alongside your operations.connected worker technology for safety compliance

7. Inconsistent Execution Across People, Shifts or Lines

“We see variability across lines or shifts — even when the process is the same.”

Even when processes are well-documented, execution can vary wildly depending on who is performing the task, when, or where. These inconsistencies lead to uneven quality, production delays, and missed KPIs, especially when variability isn’t visible or well understood.

Without a way to measure and compare performance at the individual or team level, continuous improvement efforts fall flat.

How Augmentir Helps:

  • Execution Intelligence: Augmentir analyzes execution patterns across shifts, lines, and facilities to uncover where and why variability exists.
  • Standardization Through AI: The platform uses AI insights to recommend adjustments to work instructions and training, helping bring every worker up to best-in-class performance.
  • Targeted Coaching: Managers can identify who needs support and deliver it efficiently, closing gaps faster.

workforce performance insights with augmentir ai platform

The Bottom Line: A Smarter Path to High-Performance Frontlines

Rather than blaming either training or operations, the right question is: “What’s getting in the way of great performance?”

Augmentir’s AI-driven Connected Worker Platform helps manufacturers answer that question — and act on it — with precision and speed. By eliminating the barriers outlined above, companies can build a high-performance frontline workforce that is skilled, engaged, and aligned with business goals.

Ready to break down your barriers to performance?

Let’s talk about how Augmentir can help.

 

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Augmentir and UKG are working together to create a digitally connected frontline workforce that is shaping the future of work in manufacturing.

In manufacturing, success isn’t just about machines—it’s about people. But here’s the problem: workforce skills tracking and daily work execution have been handled separately for too long. The result? Misassigned tasks, skills gaps, slower production, and higher error rates.

future of work in manufacturing with UKG and Augmentir

The solution? Modernizing workforce management by digitally connecting frontline workers with AI-powered skills management and connected worker technology.

Together, Augmentir and UKG are delivering this solution to manufacturing companies around the world. Read on to discover how Augmentir and UKG are working together to create more productive, more engaged workforces in manufacturing.

Workforce Management for Modern Manufacturing Operations

Think of it like peanut butter and jelly: great on their own, but unstoppable together. When manufacturers sync traditional workforce management with AI-powered connected worker technology, they unlock huge benefits:

UKG’s leading workforce management solution, combined with Augmentir’s AI-powered connected worker platform empowers manufacturing companies to optimize labor efficiency, streamline scheduling, reduce mistakes, and ensure compliance, all while boosting productivity on the production floor.

Manufacturing organizations that utilize both Augmentir and UKG Pro Workforce Management™ can benefit from connecting time and attendance, scheduling, and workforce data with Augmentir’s connected worker platform. Through this new integration, manufacturers can gain visibility into real-time, accurate employee information and skills tracking combined with AI-driven insights into work performance. By doing so, manufacturers can improve workforce efficiency and productivity and deliver more impactful training and support for frontline workers.

  • Right worker, right job – Workers are assigned tasks based on real-time skill assessments.
  • Training in the flow of work – No need to step away from production; learning happens in real time
  • Faster onboarding – New hires get up to speed quicker with AI-driven, step-by-step guidance.
  • Fewer mistakes, higher efficiency – Workers get exactly the information they need, when they need it.
  • Continuous upskilling – As employees complete tasks, their skills profiles automatically update.
  • Smarter capacity planning – Give production teams improved capacity planning and a better decision support tool for daily workforce scheduling and management. Proactively look ahead and see coverage gaps based on employee scheduling.

assign frontline work based on skills

 

Augmentir’s UKG connector streamlines the flow of employee data into Augmentir, providing operations leaders and plant managers with valuable insights into worker availability, productivity, training effectiveness, and more. This gives production teams improved capacity planning and a better decision support tool for daily workforce scheduling and management.

Gone are the days of outdated skills databases and generic training programs. Today, learning happens on the job, in the moment, and at the worker’s fingertips. Manufacturers can provide personalized on-the-job support to employees through Augmentir’s digital guidance, bringing training in the flow of work and alleviating potential skills gaps.

The Future of Training: Learning in the Flow of Work

Traditional workforce training methods are outdated. Long classroom sessions, dense manuals, and generic training modules don’t cut it anymore—especially in fast-paced manufacturing environments. Workers need real-time, task-specific guidance to build skills and stay productive.

That’s where embedded training comes in. Instead of separating learning from work, Augmentir enables:

  • Just-in-time training – Employees learn exactly what they need, right when they need it.
  • Mobile, interactive work instructions – Step-by-step guidance delivered on the shop floor.
  • Skills-based task assignments – Workers are matched to jobs they’re qualified for, with training baked in.
  • Continuous learning & upskilling – As workers complete tasks, their skills profiles evolve, keeping pace with job demands.

manufacturing workforce management and training development with connected worker software

This approach not only accelerates onboarding but also reduces downtime, improves accuracy, and keeps workers engaged—all while production continues at full speed.

How Augmentir and UKG are Shaping the Future of Work in Manufacturing

Augmentir’s AI-powered connected worker platform makes skills integration effortless. By delivering smart, adaptive digital work instructions, Augmentir ensures that:

  • Workers receive personalized guidance based on their experience level.
  • Skills data stays fresh, automatically updating as tasks are completed.
  • Training gaps are filled in real time, keeping production smooth and efficient.
  • Supervisors have full visibility into workforce capabilities and gaps.

For manufacturers like Armstrong World Industries (AWI), this has been a game-changer. Facing workforce shortages and declining tenure rates, AWI needed a way to ensure workers had access to the right information at the right time. By adopting Augmentir, AWI empowered its frontline workers to operate equipment, troubleshoot issues, and execute tasks with confidence—all through a single, mobile interface.

The Power of the UKG + Augmentir Partnership

The digital transformation of today’s manufacturing workforce doesn’t stop with Augmentir alone. The partnership between UKG and Augmentir takes workforce optimization to the next level.

By combining UKG’s workforce data (scheduling, time tracking, and HR insights) with Augmentir’s AI-driven skills tracking and adaptive work instructions, companies can:

  • Schedule workers smarter – Assign shifts based on real-time skill levels.
  • Close skills gaps faster – Proactively upskill employees before gaps cause production delays.
  • Improve retention & engagement – Give workers clear paths for career growth and skill development.
  • Boost operational efficiency – Match the right person to the right job, every time.

This isn’t just about automation—it’s about empowering people. When employees have the skills, training, and resources they need in the flow of work, they stay longer, perform better, and drive business success.

Bottom Line? Augmentir + UKG = The Future of Work in Manufacturing

The manufacturers that integrate digital skills tracking with connected worker technology that supports daily operations will be the ones that thrive in an era of workforce disruption. Augmentir and UKG are making it happen – helping companies close skill gaps, improve efficiency, and build a workforce that’s future-ready.

 

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

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

performance management in manufacturing best practices

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

5 Best Practices for Performance Management in Manufacturing

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

1. Clear Goal Alignment:

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

2. Real-time Monitoring and Data Analytics:

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

Pro Tip

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

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3. Employee Training and Development Programs:

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

4. Regular Performance Reviews and Feedback:

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

5. Integration with Continuous Improvement Initiatives:

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

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

Key Performance Management Strategies for Manufacturing Leaders

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

Line-shift Goals

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

Individual Meetings and Communication

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

Continuous Training

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

Performance Management Tools

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

Simplifying Performance Management with Digital Tools

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

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

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

performance management best practices in manufacturing

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

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

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

 

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