Industry 4.0 leaders are continually creating new automation and advanced manufacturing technologies to address workforce shortages, with these innovations already boosting efficiency profitability for many small and medium-sized manufacturers (SMMs). However, deploying automation, like a collaborative robot (cobot), can be challenging- often leading to underutilized equipment if it doesn't meet initial expectations.

Simply placing a cobot where a worker is absent isn't enough. A Lean, strategic approach is essential to pinpoint operational pain points that automation can effectively address. By upskilling your team with Industry 4.0 training, your company can maximize returns on investments in technology like cobots, 3D printers, or embedded automation to enhance current systems.

This article explores how Industry 4.0 upskilling- such as training in automation and additive manufacturing (3D printing)- can equip frontline workers and managers with valuable skills to advance their careers and drive business growth. Before delving into automation training, however, it's essential to focus on process upskilling to ensure a solid grasp of your current workflows and identify any gaps that may impact your investment in automation.

Operations Management Upskilling: Begin with Data

Many business leaders and plant managers lack a structured approach for tracking key performance indicators (KPIs), which are crucial for identifying and addressing operational issues before they impact financial performance.

Manufacture Nevada can help manufacturers implement enhanced operations training to establish data-driven methods. For example, using a hands-on assembly exercise, teams are tasked with producing a set number of parts within a short shift. This exercise quickly reveals process bottlenecks, such as defective parts slowing production. By visually identifying when and where issues arise, employees and managers gain actionable insights, allowing them to refine processes and improve efficiency.

This type of upskilling boosts morale and provides opportunities for small wins. For example, dashboards can be reset every hour to give employees a better chance of hitting a set of KPIs each day. Plus, technologies like process monitoring sensors are inexpensive and can show all your employees how important each worker’s contribution is to your company. This, in turn, will make employees and managers more receptive to new technologies in the future.

Enhanced operations management training helps managers, information technology teams, and business leaders become successful technology integrators. It equips them with data-driven insights to leverage Lean and Industry 4.0 manufacturing technologies to make systems implementation easier and more valuable for their teams.

Human-Machine Interaction Upskilling: Move Beyond Check Sheets

For small to medium-sized manufacturers, understanding the story behind performance data is crucial. Upskilling employees in human-machine interaction (HMI) enables them to use digital tools like tablets for real-time monitoring and control, fostering seamless communication between the shop floor and the broader company. When a machine fault occurs, an employee can log the reason code, allowing teams to collaborate and address the issue together.

Upskilling in digital process control involves selecting the right HMI to minimize process variation. For instance, if you're producing a screw with tight tolerances, tools like sensors or closed-loop controls can help maintain consistency. With these systems in place, machines can self-correct issues, freeing employees from manual check sheets to track metrics like temperature, pressure, or flow rate. This shift allows workers to focus on more valuable tasks, while leadership leverages the new data for company-wide process improvements.

Automation Upskilling: Prepare Your Floor for Cobots

At this point, you may be wondering why we are just now getting around to automation upskilling. This is because you never want to spend money on a robot or cobot without first addressing issues with your current processes.

For example, your operators may hate loading and unloading parts from a Computer Numerical Control (CNC) machine. What if you could automate this task and elevate your operators to a more quality control and oversight role? Maybe you could automate additional repetitive-motion tasks further down the production line. With the right training and automation solutions, you could remove bottlenecks that slow production, frustrate frontline workers, and cause high turnover.

Cobot upskilling can help your operator-level employees, supervisors, and maintenance personnel spot opportunities for implementing automation into your facility. It introduces them to design considerations to determine which process elements can be easily automated. Process mapping exercises help them learn how automation can reduce sources of variation.

Introduce Your Employees to 3D Printing and Industry 4.0 Upskilling

Before investing in new additive manufacturing technology, such as a 3D printer, it’s important to ask the right questions to learn where your new investment can add the most value: Which technologies are best for us? What are the best practices? How do I download a part off the Internet and create it on a 3D printer? Can I 3D print “fingers” for grippers for our new cobot?

Hands-on training is essential, such as learning the fundamentals of using a fused deposition modeling (FDM) printer and how to prevent issues such as bed adhesion or “spaghetti monsters” when an object detaches from the print bed in mid-printing.

How Manufacture Nevada Can Help

In the ever-evolving landscape of Industry 4.0, small and medium-sized manufacturers (SMMs) face the dual challenge of addressing workforce shortages while integrating new automation technologies that can boost efficiency and profitability. While advancements like collaborative robots (cobots) promise significant benefits, improper deployment can lead to underutilized equipment and unmet expectations. This is where Manufacture Nevada comes in. We emphasize the importance of first understanding existing processes before introducing automation solutions. Through our targeted training programs, we help teams identify operational pain points and ensure that automation aligns with your production needs. Reach out to our Business Advisors today to answer all your questions, and to schedule a consultation.

Content from this blog was sourced from IndustryWeek.