Let’s start with a good news, shall we?
It’s a great time to be in the industrial machinery or equipment industry. The global construction and mining equipment industry was worth a whopping 160.6 billion U.S. dollars in 2021. It’s predicted to keep growing until 2028!
The significance of these numbers lies in the correlation between increased funding and investments in the machinery & equipment industry. Typically, such investments manifest in the procurement of additional equipment to bolster upcoming projects.
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 of challenges. Let’s learn what those equipment industry challenges are and how can connected workers solve them!
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:
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.
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:
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.
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.
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:
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.
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.
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.
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.
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.
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:
Ensure Decreased Human Errors and Increased Workers Productivity.
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Chirag brings with him 15+ Years of experience in Digital Transformation, and IT Leadership. At Plutomen, he holds deep experience in business with a track record of customer-centric approaches helping them build business transformation.
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