5 Equipment Industry Challenges (And How Connected Workers Can Solve Them)

Why is the equipment industry facing significant challenges despite its impressive growth? With the global construction and mining equipment industry whopping at 160.6 billion U.S. dollars in 2021 and its predicted to keep growing until 2028, the industry is in a strong position.  The significance of these numbers lies in the correlation between increased funding and investments in the machinery & equipment industry.

Things are buzzing in North America, Western Europe, and East Asia – the key markets for this industry.

But, despite this, the equipment industry is not immune to challenges. As industrial enterprises strive to keep pace with evolving demands and technological advancements, understanding these obstacles is crucial. Let’s learn what those equipment industry challenges are and how connected workers can solve them!

How can connected workers solve equipment industry challenges?

The machinery & equipment industry, crucial for the global economy, significantly benefits from integrating connected workers platform. These platforms utilize digital tools(AR, VR, AI, ML, and IoT) to enhance the production, maintenance, and operation of tools, heavy equipment for construction and mining, and machines for energy sectors. Currently, industrial equipment (IE) manufacturers across the country manage a diverse range of machinery, including hydraulic excavators, wheel loaders, backhoe loaders, bulldozers, dump trucks, tippers, graders, pavers, asphalt drum/wet mix plants, breakers, vibratory compactors, cranes, forklifts, dozers, off-highway dumpers, drills, scrapers, motor graders, rope shovels, and more, with connected workers playing a pivotal role in optimizing their use and functionality.

Although there are numerous opportunities for growth, IE manufacturers face following significant challenges in a highly competitive market:

Challenge #1: The Skill Gap

The manufacturing skill gap is the primary factor behind the machine issues in the equipment industry. You see, experienced labor, or I can say GenZ and Baby Boomers, are slowly taking their leave from their jobs. They take their skills and knowledge with them. Hence, creates a skill gap, but the issue does not end here!

As most manufacturers use the same old technology and machinery without any automation, it becomes difficult for them to hire fresh talent as all of them are technology lovers.

Stats suggest that only 26% of employers are automating or enhancing work through technology. Moreover, as of March 2023, there are over 650,000 open manufacturing jobs. As these numbers are big and concerning, it can lead to a skill gap for an extended time for a business.

How Connected Worker Can Solve the Skill Gap Issue?

The labor skillgap issue can be solved by bringing industrial workers up to speed, ensuring they meet performance expectations. Additionally, there’s an ongoing need to continually update and upskill workers in response to the ever-evolving landscape of constant change. Connected Worker technologies, including work collaboration platforms like AR/VR, and intelligent smart-glasses, play a pivotal role in the competency management process—from recruitment and onboarding to training and ongoing competency management. Going beyond traditional learning management systems, these technologies present numerous opportunities to empower frontline workers knowledge and skills.

Attached below is an image that illustrates global adoption of different connected worker technologies as per a report provided by LNS Research.

As per the report, Connected Worker use cases with the highest potential significantly contribute to addressing critical workforce skills gaps and challenges in operational excellence across all industrial sectors. These include:

• Utilizing mobile/augmented reality to scale rare/expert skills.
• Implementing an application strategy to enhance worker engagement and retention.
• Leveraging mobile/augmented reality for digital work instructions/SOPs.
• Using mobile/augmented reality for frontline training

Challenge #2: Cost Efficiency and Safety

Cost is one of the primary aspects affecting a business’s success. And without proper technology, it becomes tough to manage cost efficiency. Some aspects that affect cost efficiency are custom demands, rising customer expectations, product complexity, on-demand production, etc. These can be tough to fulfill and may lead to lower cost efficiency.

On top of that, if a professional worker is not present for operations, it can lead to a slowing down of the production process. Thereby affecting speed. Furthermore, due to a lack of expertise, the chances of injuries may increase, ultimately challenging the safety of the workers.

How Connected Worker Can Solve Cost Efficiency & Safety Challenges?

The worst thing that can happen for frontline workers and experts is an accident on the job that causes someone to get hurt or even die. This happens especially since frontline workers require frequent travel to the sites. Frequent travelling to hazardous sites is not only risky for these workers but also for companies— since it costs a lot of money on account of travel and truck dispatches.

Connected Worker not only saves on operating costs but also revolutionizes collaboration. Field workers can now connect with remote experts worldwide, allowing less experienced workers to execute complex procedures by accessing step-by-step instructions. Two-way audio and video communication enable a shared view, promoting seamless interaction between field workers and remote experts. With 1-to-1 or 1-to-many collaboration tools, sessions can be recorded, and existing conferencing platforms from 3rd party solutions can be leveraged. This remote collaboration drastically cuts down on travel and truck dispatch related expenses for companies. Using a connected worker solution helps everyone work together to be safer by digitizing safety procedures better, collecting data, and connecting with experts remotely when needed. It’s like buying insurance for lives and preventing injuries, and it’s totally worth it for the company and the people working there. If this solution can save even one life or reduce injuries, it’s a big win for everyone.

Challenge #3: Quality Control and Compliance

As the equipment industry expands quickly, meeting regulatory standards is more important than ever. Quality control practices are vital for ensuring worker safety and the longevity of manufactured equipment in the longer run.

Making sure things are done right while manufacturing heavy equipment’s is super important, but it’s not always easy. Equipment manufacturing projects are big and involve a lot of people, complicated steps, and things that can go wrong. Here are some common problems when it comes to making sure everything is top-notch:

• Supply Chain Mess: Manufacturing companies handle a lot of equipment and materials that need to move from the shop floor to production operations. Without proper support, this could turn into a logistical nightmare. You need a solution that helps you plan machine capacity so the person in charge can assign resources to machines as needed.
• Paperwork Overload: Keeping records and documentation are crucial parts of quality control in heavy machine manufacturing industry. This means systematically and accurately documenting every aspect of the production process, from raw materials and equipment to testing and analysis.
• Human Errors: Even with rules in place, people can still make errors as they are humans afterall. Making sure everyone knows what they’re doing, checking things often, and talking to each other are key to avoiding mistakes.

How Connected Worker Can Help Overcome Quality Control and Compliance Issues?

Connected worker solution help workers with the instructions that entails how to do their jobs the right way. By following these instructions carefully, workers can make sure that they’re doing things correctly every time. This helps to maintain high-quality standards because everyone is doing things the same way, reducing mistakes and errors.

Digitized procedures like SOPs and work instructions ensure workers need to follow to make sure everything is done safely and legally. These rules might include things like wearing protective gear, using specific equipment, or following certain procedures. By sticking to these guidelines, workers ensure that the products they make meet all the necessary requirements and regulations set by authorities. This not only helps in making sure the products are safe for customers but also keeps the company out of trouble with the law.

Challenge #4: Downtime & Maintenance Issues

Tackling equipment downtime is a big challenge faced by equipment industry. As per recent stats, machine downtime can cost manufacturers around 800 hours per year. If we talk about the automobile sector, a manufacturer loses $22,000 per minute. These are huge numbers and may cost some businesses a fortune. Understanding a facility’s typical uptime serves as a diagnostic tool for maintenance and production efforts. For instance, high equipment downtime may indicate issues with preventive maintenance or production setup. Conversely, low downtime suggests a healthy production environment.

And, for businesses like telecom, it can be tough to send an expert to a remote location for repair and maintenance procedures. Therefore, maintenance issues may arise. If any technology is not involved, it can be tough to cover grounds.

How Connected Worker Can Minimize Equipment Downtime & Maintenance Issues?

Connected Worker platforms empower front line operators to swiftly communicate unresolved issues using an integrated chat function, enhancing visibility and expediting issue resolution. Front line workers can also collaborate with remote experts via AR-enabled devices, facilitating quicker troubleshooting during preventive maintenance operations.

It’s important to highlight that Remote Assistance is a last resort. Electronic work instructions and digital workflows, crafted from the best practices of your most skilled workers, aim to ensure employees always know what to do, preventing problems from escalating. However, in emergencies, remote assistance enables front line teams to connect instantly with subject matter experts who can assist in resolving issues on the spot. Unlike traditional methods, where there is no visual aid, augmented reality provides the industry workers with a super immersive 3D virtual model of the machine and its parts.

Technicians can use these 3D models to study the parts of the machines and further dismantle and repair them. An example of a company using connected worker technology solving equipment industry challenges is Bosch. Bosch allows its technicians to use an AR app that allows them to locate machine parts easily and make repairs based on the digital instructions provided by the app.

Challenge #5: Training Equipment Operators

As manufacturers upgrade their equipment, the demand for training employees to operate them efficiently increases.

In essence, new equipment often introduces new controls, emphasizing the importance of ensuring operators understand their functionality.

Furthermore, even with machinery lacking advanced software and controls, it remains highly recommended to provide operators with proper handling training.

When you have lots of equipment, remember that each machine is different. Hands-on training helps operators learn the best way to use each piece of equipment, so they don’t accidentally damage it.

Plus, well-trained operators feel more confident using the machines and can spot any issues early on, saving money in the long run.

And, proper training ensures that new hires know how to safely operate heavy equipment right from the start.

How Connected Worker Can Efficiently Train Equipment Operators?

Connected workers can use cool technology to train equipment operators better. With augmented reality (AR) powered remote assistance, trainers can guide operators from a distance, showing them exactly what to do through special glasses or screens.

On the other hand, Extended reality (XR) enabled SOPs and work instructions make learning easier with interactive 3D models and step-by-step guides. Imagine wearing goggles that show you exactly how to fix a machine or operate equipment, making learning more hands-on and fun. Also, 3D visualization with AR/VR lets operators practice in a virtual environment, where they can make mistakes without any real-world consequences. This way, operators can learn faster and better, becoming skilled at their jobs in no time.

How Plutomen Connected Worker Can Help You?

At its fundamental level, Connected Worker is an ecosystem that connects frontline workers through mobile applications or wearable smart glasses. This involves providing workers in the plant or field with mobile devices for accessing information or inputting data, such as manufacturing work instructions, safety details, or entering inspection data. Moving beyond these essentials, the incorporation of advanced digital technologies like AR, AI, and IoT has broadened the scope of Connected Worker use cases, enhancing the overall value derived from their implementation. A connected worker solution, like Plutomen, offers “on-the-job” knowledge, information, and skill transfer to industrial workers. Plutomen’s connected worker help equipment operators through applications like:

• Augmented Reality Collaboration: This feature provides powerful Augmented Reality-enabled remote assistance sessions, enabling on-site technicians to quickly solve complex problems.
• Digital Work Instructions: This tool aids workers in their tasks by simplifying the creation, deployment, and optimization of digital work instructions. It also enables the creation of guides, standard operating procedures (SOPs), checklists, and more without requiring coding. These digital workflows assist connected workers in performing their jobs to standard.
• 3D Visual Instructions: This feature empowers workers to help themselves by accessing rich training resources tailored to their needs. The training is highly visual and may include videos, 3D equipment models, and photographs, significantly enhancing memory retention compared to traditional written instructions.