The 4 Stages of the Connected Worker

Why should the industry seriously consider connecting its workforce?

The manufacturing industry has typically focused on advancing the capabilities of machines and devices, leading to some incredible achievements in data acquisition and connected cyber-physical systems.

But perhaps this focus has left the workforce underdeveloped. Issues like the skills gap and worker shortages are testaments to how the workforce lacks the necessary skills to consistently perform the complex and variating needs of the industry.

In light of this, modern manufacturers are seeking ways to bridge the gap, primarily focusing on connected worker technologies that expand the capabilities of the workforce.

But like most things, the connected worker rests on its own sliding scale, which is a good thing.

From complete people-oriented integration with cyber-physical systems to simple but effective training platforms, the entire industry has the opportunity to seize the benefits of the connected worker.

So what are the 4 Stages of the Connected Worker?

1. Stage 1: New Employee Onboarding
2. Stage 2: Direct Access to Knowledge on the Shop Floor
3. Stage 3: Real-Time Data Collection
4. Stage 4: Human-Machine Collaboration through a Digital Workflow

Before we explore each stage, it is important to note that companies don’t need to experience all 4 stages, nor do they need to experience them in the order above. The stage that works best for you is highly dependent on your operation, your products, and your market demand.

In fact, one of the main strengths of connected worker technologies is that they enable businesses to progressively connect their workforce at various levels depending on their operations and digital readiness.

Stage 1: New Employee Onboarding

Stage 1 of the connected worker is about giving workers easy access to digital reference material when they need it. This can be in the form of SOPs, training manuals, EHS (Environment, Health, & Safety) materials, MSDS (Material Data Safety Sheets), and more.

Now, PDFs, and other digital mediums can be used as digital reference material. But it's hard to qualify them as a connected worker tool for some very important reasons.

Although these files come in a digital format, you have to manage them like sheets of paper. They are typically distributed in a limited capacity, they’re hard to update, harder to find, and forgotten all too easily. Process improvements are generally not tracked and there is no guarantee that operators are looking at the most recently updated material.

On the other hand, Stage 1 focuses on easy access to documentation and intelligent document management.

A real connected worker platform within Stage 1 allows companies to manage their process documentation more easily through a complete version history. Each time a document is updated or improved, our work instruction software creates a complete history of all changes, ensuring that no training methods or documentation are lost. Users have one source of information, enabling training, onboarding, and reference material to be easily accessible.

At the same time, organizations can create individual profiles for each employee, allowing them to track employee qualifications, cross-train effectively, and strategically plan their workforce based on the specific skills of each employee.

Unlike PDFs and paper, connected worker technologies expedite training by guiding workers through the actual process. This means that users can learn new skills in a classroom setting and/or directly on the shop floor!

Plus the training process can be digitally interactive with knowledge tests/checklists that immediately appear after workers have finished the training material.

KONE, a world-leading manufacturer of elevators and escalators, uses their connected worker platform to train new employees in less time with better results.

Stage 1: Key Characteristics

• Focus on training: Interactive training material allows employees to work sooner while helping organizations manage the skills of their workforce.
• Reference material: Employees have easy access to reference material when they need it.
• Easy process management: All organization knowledge is centralized, making it easier to manage and update.

Stage 2: Direct Access to Knowledge on the Shop Floor

While Stage 1 enables workers to be trained effectively, Stage 2 guarantees that workers follow the best and most up-to-date procedures. We’re not just talking about reference material anymore, we're talking about live worker guidance.

The main goal of Stage 2 is the standardization of processes using the best knowledge and practices of the company. Through either a tablet, laptop, or computer screen at the workstation, every worker is guided through a step-by-step process. Since workers have the right instructions, they perform all key actions consistently, empowering organizations to increase quality and decrease defects and/or process deviations.

In other words, the worker performs the work while the digital platform shows them how to do it.

Real-time worker guidance is extremely beneficial for companies engaged in High-Mix Low-Volume (HMLV) manufacturing where a wide variety of products are built within limited quantities.

This level of worker connectivity to cyber-physical systems greatly expands each worker’s total knowledge capacity, enabling companies to move away from tribal knowledge and embrace digitally powered standardization.

On too many manufacturing floors, the procedure used could come down to the operator performing the work. But at Stage 2, every worker follows the best processes set out by the company. Since each worker has an individual profile, supervisors can monitor if users are following the instructions as well as monitor a worker’s productivity.

Dinel Schneider Electric remarked how using our software has greatly benefited their workforce.

The connected worker platform at Stage 2 also connects those creating the guided instructions. Like in Stage 1, a complete version history is available for all documented processes, enabling team members to see what changes have been made and who made them. With this capability, continuous improvement is easy to enact and manage.

At the same time, when instructions need to be rolled out or improved, users can create approval groups to ensure that all associated engineers and leaders sign off on the new process. Instead of sharing documents over email, losing versions, and chasing people down, our work instruction software enables key players to sign off on the process directly within the connected worker platform.

Stage 2: Key Characteristics

• Digital standardization: All best practices are digitally standardized within one centralized server.
• Live worker guidance: The user taps into their work instructions to receive live guidance while working on the shop floor. They receive the right instruction at the right time.
• Up-to-date process knowledge: All instructions are up-to-date with the latest approved procedures.
  
  

Stage 3: Real-Time Data Collection

While Stages 1 & 2 are about providing workers with process knowledge, Stage 3 enables organizations to collect process data directly from workers on the shop floor, facilitating a bi-directional flow of information in real time.

Since workers are at the core of any organization, capturing data from all worker actions allows companies to hone in on their processes and derive valuable insights.

This includes data such as

• Work order numbers
• Runtime
• Serial numbers
• Measurements
• Process and safety verifications
• Quality data
• Inspections
• Checklists
• Workforce data
• And more.

Traditional data collection on spreadsheets can often be inaccurate if operators do not collect the data in real time. For instance, if a worker fills out their spreadsheet after they’ve assembled 5 units, what’s the likelihood that the data is as accurate as it can be?

Instead, with a connected worker platform, users are prompted at key points of their process to enter serial numbers, quality data, checklists, and other pertinent information, ensuring that data collection is not an afterthought, but a key part of the process.

This level of connected worker also ensures that all information gathered comes from one source of truth. Instead of having operators gather data in separate systems, a true connected worker platform enables workers to maximize their time and capabilities with one system.

But is this real-time data collection easy?

As we said in the beginning, the main goal of all 4 stages of the connected worker is to empower the workforce. Data collection is no exception. Stage 3 enables workers to easily collect data without disrupting their workflow. All data collection is integrated into the work instructions software. Users can also use barcode scanners and other tools to quickly and accurately record serial numbers within their work instructions.

Quality inspectors can also use the technology to create detailed inspection instructions that prompt users to validate key components in the right order while collecting crucial data throughout the inspection process.

Republic Manufacturing, a leading producer of industrial blowers and vacuum pumps uses VKS to generate valuable quality data from their inspections. They then share this data with their customers to verify the proper process and inspection requirements were followed.

Stage 3: Key Characteristics

• Real-time data collection: Users and their connected environment collect data at key points of every process, ensuring that the right data is recorded at the right time.
• Centralized data: All process and worker data is stored and collected within one centralized system.
• Highly adaptable data acquisition: With highly adaptable and dynamic data collection tools such as VKS Smart Forms, organizations can collect the data they need most.

Stage 4: Human-Machine Collaboration through a Digital Workflow

Stage 4 is where an organization can seamlessly connect their workers and processes with various systems, tools, and machines through the power of IoT devices and API-enabled systems. This final stage essentially bridges the gap between the physical and digital worlds, connecting the worker to the multiple facets of their operation.

For example, our work instruction software will communicate with various machines, tools, and systems at key points within any process.

While Stage 4 brings about a whole new list of technological possibilities, this stage is mainly about enhancing worker capabilities through automation. Here are a few examples of the capabilities of Stage 4 connected worker technologies like VKS with other systems and tools.

• Smart Tools: VKS communicates with the smart tool to push, capture, and validate the correct torque from every assembly. Users don’t need to adjust any settings because the work instructions have all settings preprogrammed into the process, ensuring that only the right torque is applied every time.

• Machines & PLCs (Programmable Logic Controllers): VKS can automatically activate machines such as welding robots, label printers, test benches, and more once all required setup steps have been completed.

• Databases: Organization can connect their work instruction platform with various databases. For example, when an operator needs to validate if a tool has been calibrated, VKS will automatically verify with a database to ensure workers are using only properly calibrated tools.

• API Integrations: Organization can connect their work instructions to their ERP, MES, and BI software,, enabling them to create strong a digital thread throughout their operations and establish an interconnected source of truth. An added benefit is that users only need to interact with their work instructions, helping them to focus on their value-added work instead of multiple systems.

Stage 4: Key Characteristics

• Automate key activities: Primarily, connected worker technology at this level works to automate actions, enabling workers to focus on specific tasks while other functions are carried out in the background.
• Ultimate Error Proofing: With multiple interconnected tools, machines, and systems, errors are virtually impossible to miss.
• Centralized Source of Data: Stage 4 centralizes all data sources and creates a strong interconnected digital thread.

Are You Ready to Connect Your Workforce?

Connected worker technology has a lot to offer the manufacturing industry, from readily accessible reference data and live worker guidance to real-time data collection and connected tools/machines/systems. Connected worker platforms and technology give organizations the ability to push further into Industry 4.0 and 5.0.

However, as we said, companies should carefully choose which stage works best for their operations. It all depends on what your unique production needs and your level of digital readiness.

With that being said, how will you connect your workforce?