It’s not just advanced machinery that is revolutionizing the manufacturing industry. Connected workers are quickly emerging as game changers. With the help of technology, they’re redefining manufacturing workflows to enhance productivity and minimize asset downtime. By 2029, the global connected worker market is expected to be valued at 21.73 billion. This article dives into the factors driving this work model, and its impact on the manufacturing industry.
What is a connected worker?
Connected workers refer to employees on the shop floor who can leverage advanced digital tools to complete daily tasks. They may use different types of technology including the Internet of Things (IoT), augmented reality, cloud computing, data analytics and performance management digital solutions. This allows them to maintain real-time control over different aspects of the manufacturing processes.
For example, IoT sensors may alert supervisors to a workstation that isn’t working. Similarly, digital visual management boards may be used to keep track of production rates so floor managers can reallocate resources wherever required.
Types of connected workers in manufacturing
Connected worker technology can be useful for everyone in a manufacturing unit. The most common types of connected workers seen in manufacturing are:
Connected Operators
Connected operators use digital tools for on-floor operations, training, worker safety and quality management. They may also be able to automate tasks and process handoffs to maintain a seamless workflow.
Connected Engineers
Engineers connected to platforms that display current production KPIs can get real-time alerts allowing them to make software and hardware changes as required.
Connected Executives
Manufacturing executives can use technology to keep an eye on production statistics remotely and make data-driven decisions.
Connected Field Workers
Field workers such as distribution agents can leverage technology to read schematics and other such details on mobile devices and use mobile devices to stay connected to other members of the team.
Why the manufacturing industry needs connected workers
Connected worker platforms offer a wide range of benefits to manufacturing units. 80% of Industrial Transformation leaders who adopted Connected Worker Platforms have seen quantifiable value from their initiatives. This includes benefits in the form of:
Easy access to information
Connected Worker Platforms make it easier for everyone on a manufacturing team to access mission-critical information. On the one hand, new employees can easily access instructions and training resources. This reduces new operator onboarding time and helps them become productive faster.
On the other hand, they can quickly troubleshoot issues on the plant floor through problem-solving visual management boards. As a result, processes flow smoothly and downtime is reduced.
Easier communication
Connected Worker Platforms allow workers to stay connected to the rest of the team from wherever they may be. This facilitates collaboration and real-time troubleshooting.
For example, supervisors can send quality alerts to workers operating machines that are churning out products with a higher-than-accepted defect rate. Similarly, operators can chat with engineers to troubleshoot technical issues.
Lower rate of production errors
Connected workers have access to standardized instructions and visibility over the entire manufacturing process. This lowers the risk of misunderstandings and the errors they could lead to. It also enables consistent quality control and early identification of process non-conformances.
For example, a connected worker using a smart torque wrench on an automotive assembly line can get automatic alerts if they apply the wrong torque. Further, the tool maintains digital records for future audits.
Higher employee engagement
Connected Worker Solutions are beneficial for all types of workers. Procedure checklists can make it easier for employees to switch from one task to another. Connected Worker Solutions also give them a way to share concerns and get immediate resolutions. This makes them feel valued, heard, and more confident on the job, and allows them to share their knowledge.
Knowing they will have access to digital technology also makes manufacturing units more appealing to a younger workforce. This generation is used to working with technology. In this way, they can work faster and be more efficient.
Increased transparency
Connected Worker Platforms help collect process data and turn it into actionable insights. This also brings about transparency in worker performance. It breaks down information silos and ensures that everyone is on the same page. Further, it allows workers to report issues and share feedback openly thus curbing misunderstandings.
Safer workspaces
Implementing connected worker systems can improve overall safety in many ways. Firstly, it makes it easier to document incidents on the spot. Management can then issue standardized instructions to avoid such instances in the future. It also makes it easier to track employee certifications and training completion.
Similarly, smart helmets and other wearable devices can give workers real-time alerts if they are at risk of having an accident.
Connected worker use cases in manufacturing
Now that the benefits of connected worker systems are clear, let’s take a look at a few use cases.
End-to-end visibility: Progress tracking markers allow team supervisors and management to get a clear picture of individual performance and schedule adherence.
Quality control: Connected workers can access the information and the tools required to ensure that every piece leaving the line meets quality standards.
Machine monitoring: Real-time alerts from machine sensors can give engineers visibility into machine state dashboards. Simultaneously, when technicians work on machines, they can access all the historical information required to reduce downtime.
Distributed workforce: Visibility over overall performance and progress towards targets makes it easier for management to allocate resources effectively and manage a distributed workforce.
Effective team meetings: Easy access to real-time data cuts down on ambiguities and puts everyone on the same page for effective discussions.
Connected worker solutions
Some of the most popular connected worker solutions for the manufacturing industry are:
Wearables and Smart Devices
Smart watches, AR headsets and other such wearable gadgets can help workers seek and receive remote assistance as well as get notifications for safety hazards.
IoT-Enabled Tools
Tools and machines with inbuilt sensors can help standardize steps where precision is key and flag instances of non-conformance. These IoT sensors can also store and share data for improved traceability and performance evaluations. Further, the sensors can support predictive maintenance scheduling.
Augmented Reality (AR) and Virtual Reality (VR)
AR and VR devices can be very helpful for training new hires and troubleshooting issues.
Digital Workflows Platforms
Digitizing instructions for tasks, data sharing, workflow tracking and analytics streamlines communication, reduces the risk of errors and enables continuous improvement.
By connecting this platform to the IoT sensors and other data sources, it can also provide centralized data reporting for a more informed view of a unit’s Key Performance Metrics.
Embracing Connected Worker Solutions
There’s no doubt about it, connected workers are transforming the factory floor. There are a wide variety of solutions available today. Platforms like Fabriq are designed to improve communication, productivity, and safety for frontline manufacturing teams.
By enabling real-time data sharing for digital workflows, it reduces the risk of error and streamlines operations. Fabriq can be integrated with other Business Intelligence tools to deliver analytical reports on opportunities for growth and improvement. The result- a more efficient, more agile system that puts you ahead of the competition.
