When we talk about digital transformation, many people think of robots, AI, technologies and machines that are intended to replace human labor. However, humans will always play an important role in the production environment.
A successful digital transformation is therefore not about implementing technologies that replace people, but about enabling people to work more efficiently, make better decisions with more information and enjoy greater convenience.
Today, let’s talk about the role of people in the IIoT (Industrial Internet of Things Landscape). What is a “connected worker” and what are the benefits of a digital shopfloor? Find out that and more in this article!
The majority of workers in industrial companies are employed in manufacturing, field service or similar non-office-based jobs. In many places, paper-based processes are still used, such as the production of components based on work instructions on paper. This results in mountains of documents and folders. Fortunately, the digital transformation is not stopping here either. Work in the production environment is changing and companies can take advantage of the benefits of digital tools here too!
Due to the advantages offered by the support of a digital store floor, more and more workers are not only open to new technologies, but also want technological support.
What is a “connected worker” or “networked worker”?
The networking of workers does not only affect the people on the store floor itself. Digital solutions are changing (and improving!) the working environment of people at all levels of the company. While connected workers benefit from fast-responding systems, digital solutions also bring many advantages for managers. Thanks to connectivity, they gain better insights into store floor processes.
“Every employee who is integrated into his/her environment through networked technologies is a ‘connected worker’.”
What makes networked technologies special is that data is exchanged with other systems in real time. In this way, workers are integrated into a larger system (consisting of hardware and software components). The workers thus become part of a real-time data system.
By supporting networked technologies, workers are empowered to work more productively. This is reflected in better results, more efficient decisions and increased data quality.
What are the benefits of connected workers and the use of new technologies on the store floor?
If employees on the store floor are integrated into a networked system, this brings many advantages.
- More transparency: Connected workers generate data while they work. This means that individual process steps along the entire value chain become traceable and transparent. For example, you can quickly determine where the component is in the production process and which steps are still outstanding.
- Less error-prone processes: If workers are equipped with digital tools, quality checks can be carried out directly at the point of production and errors can be detected at an early stage. This can significantly improve quality, especially in manufacturing processes with many subcontractors.
- Better knowledge transfer: As networked workers have access to all relevant information – exactly when they need it. The onboarding of new employees can be significantly improved through interactive work instructions, for example.
- Better communication: Networked employees have the tools they need to work better together. Important information can be forwarded to colleagues easily and without wasting time, and communication is contextualized and direct.
Which technologies are suitable for digitizing the store floor?
An important prerequisite for the digitalization of the store floor is the integration of various technologies. Let’s take a look at the technological possibilities.
Platforms
The platform on which components are connected and which enables the management and provision of connected end devices forms an important basis. It serves as an important link between the data-collecting end devices and consists of a range of integrated software functions that improve decision-making, operational transparency and controllability of machines and systems and enable the management of objects in plant-intensive industrial landscapes. By processing in the cloud, collected data can be analyzed in real time.
Smart Sensors
In addition to manual data collection by humans, smart sensors and IoT devices complete the data collection process. Data is recorded via sensors and transmitted to the relevant system in real time. The application is particularly useful for recurring checks such as temperature checks.
Interfaces and mobile devices
Rigid human-2-machine interfaces that are directly linked to machines have had their day. Modern manufacturing companies now have tablets and smartphones on the machines, which can be used to control commands flexibly and on the move.
With mobile devices, workers and decision-makers have the great advantage of always having relevant information at their fingertips and being able to document it seamlessly. A mobile solution for data collection is particularly important for quality checks during tours in order to avoid time-consuming data collection on paper. Mobile devices are also suitable for daily store floor meetings on the production floor to view data or document problems.
How do I achieve a networked store floor?
The digital transformation of the store floor sounds like a major undertaking. But don’t let it put you off. Because the good news is: it’s worth starting small!
It is good to start with small steps. A misconception that prevails in many companies is that digital transformation is “one big project” that has to be completed. Quite the opposite: the transformation to a digital company is not a one-off project, but rather a continuous process. Turning everything upside down at the same time involves more risk and is more likely to lead to uncertainty among employees.
As a rule, the best way to implement digital solutions is to start with small pilot projects (or proof of concepts). This allows you to gather practical know-how and see how digital solutions work best in your company.
Step 1: Identify your use case
Determine which processes, activities and communication channels you want to digitize. Find out what data you need to measure your success and make better decisions.
Before you start implementing new technologies and software, ask yourself the following questions:
– What exactly do your existing processes look like?
– What problems should be solved or improved?
– What information and data is relevant for you?
– What information and data is best suited to measuring performance?
Talk to your employees to find out what problems and points for improvement exist and to understand them better.
Step 2: Start a proof of concept or pilot project
A clearly defined use case is best suited for this, the further development of which brings many benefits at manageable investment costs.
A proof of concept or pilot project can be used to determine on a small scale whether the new technologies solve the problems or improve performance. Use data and performance indicators to measure these effects.
Active communication with your employees is essential: when introducing new solutions, communicate with your store floor staff about the improvements that are to be achieved with the new tool. If necessary, offer your staff training on the new tools.
Following the proof of concept or the pilot project, take stock of the results and plan the next steps based on these findings.
Step 3: Further expansion of digital solutions
Use the findings from pilot projects to better implement the next steps! With the help of smaller start-up projects, know-how on digitalization projects can already be built up internally.
If a solution proves successful in small start-up projects, you can expand it to other areas and implement it on a larger scale.
Collect feedback and continue to improve your store floor with digital tools.
Use cases: Examples of “Connected Worker” use cases in industrial companies.
To make the topic of “Connected Workers” even more tangible, we present a few more examples of use cases here.
Occupational safety
Hazards, defects, safety inspections and tests can be recorded digitally and in a time-saving manner on mobile end devices and contribute to an increase in safety.
Field Service
Employees in the field are supported by digital solutions and have easier access to all the information they need.
Digital recording and documentation of quality controls.
In contrast to analog documentation, it is possible to see immediately and at a glance when and where errors occur.
The “Connected Worker” on the store floor is therefore not just a concept, but represents concrete opportunities for industrial companies to support their employees and work more effectively.
Conclusion
Supporting workers in industrial companies with digital, networked technologies is an essential building block in the digital transformation.
The idea of the “networked worker” is not a dream of the future, but can be achieved right now by implementing new technologies. It doesn’t have to be a big, risky challenge, but quite the opposite: start with a small pilot project and then expand the networking technologies step by step in the company.
