Manufacturing managers will realize the best returns on smart automation tools if they ensure that their workforce has the skills to use the equipment. TBM Consulting reports that this is one key to reaping the benefits of advanced automation in the factory. The consultants also list deciding which tasks to automate and Industrial robot arms. Credit: Wikipediawhich equipment to replace as critical choices for successful automation programs.

Automation offers the lure of reducing the human workforce while increasing quality and efficiency. Without a team that can operate sophisticated equipment, though, a manufacturer cannot achieve these goals. Workers need to know how to load software, interpret output, and support data analytics.

“With downtime being a silent killer, it’s essential to build a smart workforce around the supplemental systems and analytics that track root cause and counter measure tools in real time,” Ken Koenemann, VP of TBM Consulting, pointed out.

Workers with this level of skill are in short supply. Employers can explore training tools such as augmented reality (AR) to upgrade the skills of current employees. The use of AR reduces the number of human trainers—also in short supply—required to do the training.

Choosing tasks to automate is another potential stumbling block. Conventional wisdom is to let humans and machines do what they each do best. Understanding how to translate this guidance into a workable plan requires careful analysis. One example TMB offers is using optical inspection to identify bad spots in potatoes and then using an automated blade to cut out the spot. The automated blade works faster than a human; the combination of human skill with an automated process maximizes the advantages of each approach.

Replacing equipment is expensive. Manufacturers face decisions about which equipment to replace, and in what order, to maximize the benefits their capital expenditures can return. Switching to a fully-automated plant is a goal that will be realized slowly.