Workforce Efficiency Solutions

It’s a sobering picture for today’s manufacturing COOs...... Unfilled orders have surged to record levels..... job openings are declining...... and productivity remains stalled. All the while there's a real crisis unfolding as experience departs. ⚠️ 84 % of manufacturers say the loss of experienced personnel is hurting quality, efficiency, and productivity. Even worse - serious injuries and fatalities are soaring - hitting numbers we haven't seen in 20 years. Inflationary pressures and supply disruptions are squeezing margins, but the widening skills gap may be your biggest risk. 📈 As experienced workers retire or leave, your knowledge walks out the door. 📉 New, less experienced personnel struggle to keep pace, leading to increased safety incidents, stalled productivity, and missed orders. What can you do? ➡️ Capture critical expertise now— digitize work instructions, SOPs, and capture best practices at the corporate level with tools that make them all accessible at the point of work. ➡️ Upskill and reskill your frontline workforce rapidly with interactive training and AI‑driven guidance. ➡️ Empower your teams with real‑time data, collaboration tools, and decision support to improve safety and prevent errors. Finally, true productivity pathfinders look beyond the factory walls. They orchestrate supply networks to flexibly deliver a product portfolio that uniquely creates value for their customers. They invest in their people not just as labor but as the stewards of quality and innovation. LNS Research helps executives benchmark against peers, provides the latest insights to closing the skills gap, and develops a strategy that goes beyond resilient to sustainable. To Scale Connected Frontline Workforce Applications for continuous learning and decision intelligence, adopt Virtual Operations Center approach to break down silos, and embed an operating model so that local improvements cascade through the entire value chain to enhance safety, quality, competency, and productivity at all levels of the organization. 🔔 Follow Matthew Littlefield, Niels Erik Andersen, James Wells, Vivek Murugesan, and Michael Carroll for the latest to help you protect quality, productivity, and, most importantly, your people. #CFW #Manufacturing #Transformation #TheGreatGoodbye

Your machines and people are draining your margins. The hidden cost eating away your manufacturing profits You have the raw material. You have the machines. You even have the demand. But your production is still delayed. Because your workforce isn’t aligned to your operations. - Skilled technicians are scheduled when no high-skill tasks are running. - Maintenance teams are overworked during peak load. - Project deadlines are missed due to poor shift planning. - Plant downtime increases because human resources are reactive, not predictive. It’s a planning issue. One mid sized FMCG manufacturing unit in Gujarat was losing ₹1.2 Cr/month due to idle labor hours, rework, and unplanned overtime. They ran a 3 month pilot with predictive staffing models: 1) Workforce demand synced with production load 2) Skill mapped scheduling for critical batches 3) 24x7 visibility into shift gaps and role clashes 4) Plant uptime increased by 18% In manufacturing, efficiency comes from planning smarter. If you're running plants without syncing workforce planning to production cycles, you're building inefficiency into your business model. Sooner or later, your margins will show it. #Manufacturing #WorkforceEfficiency #PredictivePlanning

Upscale and Reskill Talent at Manufacturing Sites In today's rapidly evolving manufacturing landscape, companies continuously seek innovative ways to enhance productivity, improve efficiency, and stay ahead of the competition. With the integration of Artificial Intelligence (AI) to upscale and reskill talent at manufacturing sites and leveraging AI-driven solutions, organizations can optimize operations, empower their workforce, and achieve unprecedented success. 1. Identifying Skill Gaps through Data Analysis Machine learning algorithms and predictive analytics can analyze vast data and identify skill gaps within the manufacturing workforce. By examining factors such as employee performance, historical data, and industry trends, organizations can gain invaluable insights into areas where upskilling and reskilling efforts are required. This data-driven approach enables targeted training programs, ensuring employees receive the specific knowledge and skills needed to thrive in their roles. 2. Personalized Learning Paths It is crucial to provide personalized learning paths for each employee. AI-powered platforms can assess individual skill sets, learning preferences, and career aspirations to create tailored training programs. By offering personalized learning experiences, organizations can foster employee engagement and motivation and accelerate their professional growth. 3. Virtual Reality (VR) and Augmented Reality (AR) Training VR and AR technologies are revolutionizing training methodologies in the manufacturing sector. These technologies enable employees to simulate real-world scenarios, practice complex tasks, and develop critical skills in a safe and controlled environment. By leveraging VR and AR training programs, organizations can enhance the learning experience, boost knowledge retention, and improve operational efficiency. 4. AI-Enabled Performance Support AI-driven performance support systems provide real-time guidance and assistance to employees on the manufacturing floor. By utilizing sensors, IoT devices, and AI algorithms, these systems can monitor operations, identify potential bottlenecks, and offer actionable insights to optimize workflow. Furthermore, AI can provide instant feedback and suggestions to enhance employee performance, ensuring high-quality output and reducing errors. 5. Collaborative Robots (Cobots) Collaborative robots, "cobots," are designed to work alongside human workers, complementing their skills and capabilities. Cobots are equipped with AI algorithms that enable them to learn from human operators, adapt to changing production requirements, and perform repetitive or physically demanding tasks. Manufacturers can enhance productivity, improve workplace safety, and free up human resources for more complex and strategic assignments by deploying cobots. Embracing these best-in-class strategies will empower the manufacturing workforce, foster innovation, and pave the way for a successful future.

Understanding Workforce Challenges in Energy & Power Sector: My Takeaways and Solutions   As someone who has spent years in the trenches of industry, I see a growing challenge that’s hard to ignore; a) Plant jobs aren’t appealing to the younger generation anymore b) The new generation is not impressed by big names or brand loyalty anymore. For decades, working for a reputed company was a badge of honor, a status symbol. Not anymore! Compensation, once a key driver, is no longer enough. Younger talent values flexibility, purpose, and innovation just as much as pay (Needless to say compensation structure has to be competitive to attract talent)   Some Key figures for all of you:   - 25% of the workforce is nearing retirement   - 40% employees have left the sector for other industries since 2016 - 50% of Gen Z and Millennials reject employers based on environmental and ethical concerns   These statistics reveal a multi-faceted challenge: aging workforce, talent migration, and shifting generational priorities. The risks for operators are real: high attrition, knowledge gaps, and competency mismatches can lead to inefficiencies, safety issues, and higher operational costs.   But there’s hope. By reimagining workforce strategies, we can turn these challenges into opportunities. How do we make plant jobs more attractive? Here’s what I believe can make a difference:   Modernize Work Culture: The plant environment needs to evolve. Embrace flexibility. The new generation is not lazy, they are only against slavery. Hybrid work, upskilling, and wellness initiatives are no longer optional—they’re necessary to retain top talent. They’re the foundation for retention in a post-pandemic world. Link Purpose to Work: Highlight how roles contribute to solving global challenges, like sustainability and energy security. Show them they’re not just operating machinery; they’re powering a better future Workplace Innovation: Bring tech into the equation. Smart plants, automation, and AI-driven operations can attract tech-savvy minds. However balance automation with human competency: Technology can enhance efficiency, but only a skilled, adaptable workforce can navigate complexity under pressure. Preserve Institutional Knowledge: Need to institutionalize knowledge transfer and experiential learnings. Use robust platforms to store and transfer all knowledge. No one here is here to work till retirement now. Celebrate Plant Heroes: Recognize and amplify stories of plant workers solving critical challenges. Showcase them as innovators and leaders                                                                                                                              What’s your perspective on these workforce trends? Are you seeing similar challenges in your organization?  What should we do to make plant jobs exciting for new generation. #Leadership #WorkforceDevelopment #FutureOfWork #SkillsMatter   Engro Polymer & Chemicals Ltd Engro Corp Engro Corp  

MES/MOM Solutions: Elevating Manufacturing Efficiency  Implementing a MES/MOM Solution can revolutionize your manufacturing, driving functional improvements for enhanced efficiency, visibility, and decision-making. Here's a condensed overview:   Real-time Data Visibility: Gain insights into machine status, production rates & quality metrics. Enable faster decision-making through real-time monitoring. Production Scheduling and Sequencing: Optimize processes, minimize downtime, & enhance resource utilization. Improve efficiency through advanced scheduling. Quality Management and Traceability: Ensure adherence to quality standards with real-time inspection. Enable traceability throughout the production process. Workflow and Process Standardization: Establish standardized workflows, reducing errors. Enhance consistency with standardized processes.    Work Order Management: Prioritize, assign, & track tasks effectively for streamlined operations. Ensure efficient work order management. Resource Management: Optimize manpower, equipment, & material allocation. Achieve efficient resource utilization. Reduced Lead Times  Streamline processes for reduced lead times. Respond quickly to market demands. Inventory Management: Minimize stock-outs through efficient inventory management. Enhance supply chain efficiency. Automated Data Collection and Reporting: Reduce manual data entry with automated reporting. Ensure accuracy and timeliness. Non-Conformance & Corrective Action Management: Identify and manage non-conforming products swiftly. Enhance product quality and compliance. Resource Maintenance & Equipment Efficiency  Gain insights into equipment performance, improving OEE. Optimize maintenance schedules. Energy Consumption Optimization: Track & analyze energy consumption data for cost reduction. Identify opportunities for energy optimization. Labor Tracking & Performance Analysis: Monitor workforce performance & measure productivity. Enhance labor efficiency through data-driven insights. Regulatory Compliance & Reporting: Ensure compliance with industry regulations. Streamline regulatory compliance processes.   Continuous Improvement Initiatives: Leverage data-driven insights for continuous improvement. Foster a culture of operational excellence. Integration with Enterprise Systems: Seamlessly integrate with ERP, SCM, PLM, & other systems. Enhance data flow & decision-making. Embrace MES/MOM capabilities to drive operational efficiency, elevate product quality, and achieve superior manufacturing performance #mes #strategy #manufacturers