Tips for Balancing Automation and Human Workers in Manufacturing

Unilever shows us: productivity isn’t just about buying better tech; it’s about building better systems of people and technology working together. As Unilever’s Global Head of Ops said, they don’t separate investment in automation from investment in people. That mindset, designing roles, routines, and decision-making to match what the tech enables, turns capital spend into a competitive edge. Here’s what internal Org Development & Org Design can actually do to make that happen in #CPG: 1. Make tech and talent one system, not two: How to: - Don’t bolt tech onto old ways of working. - Start by assembling cross-functional teams: operators, IT, managers, and have them co-design workflow and KPIs together, from day one. 2. Define the new decisions, not just the new machines: How to: - Map what decisions move closer to the front line or become automated. - Run facilitated workshops to clarify “who decides what now” and ensure everyone has authority to act where it counts. 3. Build fast-feedback learning cycles on the floor: How to: - Create standing weekly or daily “factory pulse” huddles to surface issues from the floor, test improvements, and adjust quickly, turning problems into improvements instead of waiting for reports. Why this matters: 1. Tech doesn’t fix bad structure. 2. You can buy smarter robots, but if your teams don’t know how to adapt and own the new ways of working, you’ll end up paying more for the same headaches. Unilever shows that the real payoff comes when OrgDev and OrgDesign shape the system to use the new tools well, and that’s how you build a manufacturing operation that can keep pace. https://lnkd.in/gnMd5Qcm #CPG #OrgDevelopment #OrgDesign #ManufacturingExcellence #TechAndTalent #Productivity

Manufacturing Automation – Automating the wrong thing.   Only Automation that amplifies the worker increases productivity!   At all times, there are technological options that can automate a particular step or task in the process but before we proceed headlong to deploy it, we need to ask: “Is this automation increasing productivity or adding complexity and needless costs?”.   A rationalized, controlled and understood process can be performed manually, semi-automatically or fully automatically with appropriate consideration of the current state, and can be improved with some degree of next level automation. A simple test that may be applied as to the efficacy of the proposed automation is to ask the question:   “Does the automation meet the criteria of:   -        Allocating Power and Precision functions to the machine, while,   -        Allocating Perception and Dexterity functions to the worker?”   If the answer is YES, then more likely than not, the automation will deliver INCREASED PRODUCTIVITY!   If the answer is NO, then most likely than not, the automation will NOT deliver INCREASED PRODUCTIVITY and even worse, may trade manual operation challenges for automated shortfalls and reliability issues!   Further, if the answer is NO, then more likely than not, the automation is creating just as many FRICTION POINTS in the process as it’s solving.   Only Automation that amplifies the worker increases productivity! -- A post by Florian Palatini features an excellent example of the advantages of this approach by showcasing a truck unloading solution which eschews the fashionable, AI driven, Autonomous Robotics solutions laden with undeveloped technology and dripping with reliability and “Edge Case” exceptions. In this solution, the human operator is much more flexible and once unburdened from the Power and Precision requirements … much more PRODUCTIVE! Florian’s Post Here: https://lnkd.in/e_eTKR7s   -- “In addition, production rate reliability and repeatability will go up while operator skill levels required and operator fatigue levels will go down, leading to a safer and more profitable production line.”   --   Are you properly sizing your automation?   Your thoughts are appreciated and please share this post if you think your connections will find it of interest.   Leave a comment or connect with me to discuss how to strategically plan automation for enhanced productivity.   https://lnkd.in/ehsAQcMu #industry40 #cobots #ai #machinedesign #automation #manufacturing #productivity

Redefining Manufacturing: Lessons from Tesla's Automation Journey Industrial automation is a $500 billion puzzle that can stump even the most seasoned and creative minds. Elon Musk’s journey in automating its car production - notably the Model 3 - exemplifies the challenges behind the promise of AI and Robotics. When automating an inefficient or misunderstood process you further entrench a problem rather than move towards a solution. Tesla's ambition was to revolutionize car manufacturing with extensive automation for its Model 3 production. This vision was part of a broader industry trend where manufacturers envisioned a future where machines handled complex tasks, reducing human error and increasing output. However, this promise requires a deep understanding and restructuring of existing processes. Tesla encountered numerous challenges in their automation attempt, a period Musk referred to as "production hell." The highly automated system, plagued with technical glitches and bottlenecks, significantly slowed down production. Complex tasks like wiring and aligning parts were particularly troublesome for robots. During process mining we find that actual behaviors of people and organizations often differ from the intended, designed, or expected behaviors. The most common process flow along with variations, loops, dead ends and unexpected events all conspire to make it much harder to implement an automated system. Initially, Tesla focused on replacing many human roles with machines, underestimating the value of human creativity, problem-solving, and flexibility. This overemphasis on automation without sufficient process observability led to a lack of adaptability in handling variations and exceptions in manufacturing processes. Faced with these challenges, Tesla had to reevaluate its approach. The company scaled back some of its automation efforts and reintroduced more human workers into the production line. This move highlighted the importance of human skills and adaptability in manufacturing, showing that the ideal manufacturing process may be a blend of both automation and human labor. Tesla's automation journey illustrates that while automation is a powerful tool, it is not a one-size-fits-all solution. Successful automation in manufacturing requires a deep understanding of existing processes, a willingness to adapt, and a balanced integration of human and machine strengths. This approach not only optimizes production but also paves the way for more innovative and resilient manufacturing practices. OkusAI is focusing on the "Production Hell" painpoint .

Stanley Black & Decker's experience with the Craftsman factory in Fort Worth offers a sobering reminder that advanced automation is not a one-size-fits-all solution to the complexities of modern manufacturing. While the goal of creating a highly automated, efficient, and domestically-located manufacturing facility was admirable, the practical difficulties of implementing such a system were underestimated, revealing an important lesson: Technology can enhance efficiency and productivity, but it cannot fully replace the nuanced expertise of seasoned human workers. It's crucial to strike a balance between leveraging automation for efficiency and retaining the irreplaceable craftsmanship that experienced professionals provide. Additionally, reshoring operations is not merely about bringing jobs back home; it involves navigating logistical, cultural, and operational challenges that demand careful planning and execution. #robotics #manufacturing #automation https://lnkd.in/gzQYWpj8.

Organizations that rely solely on replacing human workers with AI technologies may face negative consequences. The article argues that successful companies of the future will be those that effectively combine human capabilities with AI, fostering collaboration and leveraging the unique strengths of both. 🤖 The article cautions against a complete replacement of human workers with AI, as it may lead to the loss of human touch, creativity, and problem-solving skills that are vital for innovation and customer satisfaction. 🤝 Successful companies will be those that integrate AI technologies into their operations to augment human capabilities, enabling employees to focus on higher-value tasks that require emotional intelligence, complex decision-making, and interpersonal skills. 💼 The article highlights that organizations should invest in upskilling their workforce to work effectively alongside AI technologies, ensuring they have the skills and knowledge to collaborate with AI systems. 💡 AI should be viewed as a complement to human workers, assisting in automating repetitive tasks, providing data-driven insights, and enhancing productivity rather than replacing entire job functions. 🌱 Building a culture of trust and transparency around AI adoption is crucial, fostering employee buy-in and ensuring the ethical and responsible use of AI technologies. The integration of AI into the workforce should prioritize collaboration and augmentation, rather than complete substitution. By recognizing the unique strengths of both humans and AI, organizations can create a harmonious and productive working environment. Companies that effectively combine human skills with AI technologies will be better positioned to drive innovation, adapt to changing market dynamics, and achieve long-term success. #AIandHumanCollaboration #AugmentedIntelligence #WorkforceUpskilling #Innovation #EthicalAI

Excellent Paper from the World Economic Forum In the insightful paper "Views from the Manufacturing Front Line: Workers' Insights on How to Introduce New Technology," Kyriakos Triantafyllidis of the World Economic Forum and Thomas Bohné from the University of Cambridge unveil a comprehensive analysis of modern challenges in the manufacturing sector. This pivotal study, from over 85 interviews with front-line workers across diverse US, European, and Asia industries, highlights how companies can effectively respond to the growing demand for customized products, address skill gaps, and manage demographic shifts like an aging workforce. A key takeaway from this World Economic Forum-endorsed report is the necessity of integrating advanced technologies, such as extended-reality headsets, exoskeletons, and cobots, into manufacturing processes. The study's core strength lies in its employee-centric approach, valuing firsthand insights from those on the shop floor. It underscores the importance of involving workers in technology adoption, enhancing human-machine interactions, and ensuring employee buy-in for successful implementation and retention. Significant insights include the need for comprehensive pre-introduction preparation, where managers effectively communicate the benefits and decision-making processes to employees. The report also highlights the advantage of involving workers in decision-making, like contributing ideas and participating in risk assessments, which boosts acceptance and practical application of new technologies. A notable innovation is the concept of 'super users' or 'technology champions' during training, catering to diverse learning needs for effective adoption. However, the report could be further enriched by adding insights from employees in the Americas region and addressing areas like the absence of specific metrics to measure technology integration success, potential overreliance on worker input, resource management challenges, and risks associated with technology overload. Additionally, it could benefit from a more nuanced discussion on balancing local and global business needs and a deeper exploration of the impact of organizational culture on technology adoption. In essence, while offering a thorough, worker-focused framework for introducing technology in manufacturing, the report presents opportunities for improvement, particularly in incorporating a more comprehensive range of worker perspectives, establishing concrete metrics, finding the right balance between management and employee inputs, managing resources efficiently, and acknowledging the influence of organizational culture. #employeesinsightsonhowtointroducenewtechnologies #Topnotchfinders #sanfordrose

𝗖𝗼𝗺𝗺𝗼𝗻 𝗣𝗶𝘁𝗳𝗮𝗹𝗹𝘀 𝗼𝗳 𝗔𝘂𝘁𝗼𝗺𝗮𝘁𝗶𝗼𝗻 (𝗔𝗻𝗱 𝗛𝗼𝘄 𝘁𝗼 𝗔𝘃𝗼𝗶𝗱 𝗧𝗵𝗲𝗺) 🚨 Automation can be a game-changer—but only when it’s aligned with your people, processes, and purpose. When thoughtfully designed, automation empowers teams, streamlines operations, and unlocks creativity. Here are some powerful takeaways: 🔹 Start with strategy, not just tools Effective automation begins with knowing the why. Map the workflow, define the goal, and use tech to support—not replace—your people. 🔹 Strengthen what works before scaling it Optimize your current processes first. Then automate to amplify efficiency and clarity. 🔹 Communicate early and often Bring your team along. Share the purpose behind the changes and offer support that builds confidence. 🔹 Design for simplicity The best automation removes friction. When it feels seamless, it fuels adoption and excitement. 🔹 Support human decision-making Let automation handle the repeatable tasks—so your people can focus on what they do best: creative, critical, human thinking. Done right, automation doesn’t replace people—it elevates them. It helps teams spend more time on meaningful work, improves morale, and drives innovation from the inside out. 📖 Read the full Forbes Coaches Council article and share your thoughts below. https://lnkd.in/ecYwq7JF #AutomationDoneRight #SmartLeadership #DigitalTransformation #HumanFirstTech #ForbesCoachesCouncil #FutureOfWork #EmpoweredTeams

Manufacturers must adapt and change to stay relevant to their customers, stakeholders, and employees. AI and Gen AI will play a crucial part in the reinvention of industrial organizations. How companies approach AI will be critical in successfully embedding this powerful tool across the organization. Here are a few things to consider on the journey: 👉 Leadership must build a culture that embraces technology as a means to support the employee, rather than eliminate roles. There is more than enough work to be had that demands more critical thinking from the workforce. 👉 Strong change management is the foundation for successful improvements. We often forget that we are farther along the change curve and need to help others to understand why the new change is important for each of those effected and the business. 👉 Transparency is critical for the newer generation of workers. Technology can play a key role in ensuring that communications are multi-directional. Connected Frontline Workforce #CFW applications provide tools for the nearly 80% of employees who have been too often left out of the loop. 👉 Messaging must include what the change intends to accomplish, what the change has enabled, and what is next on the journey. Ensure lines of communication are open to address concerns and opportunities along the journey. 👉 Gen AI can be a key enabler to upskilling the workforce. During implementation, use cross-functional teams to pilot use cases that address pain points and align with business priorities. The work that needs to be done will remain the same. Yet industrials must realize the critical need to redesign the way work is done to improve safety, productivity, and sustainability for the business. What are your thoughts on how to successfully embed AI and Gen AI? Consider sharing this with your network to deepen the conversation. #FutureOfWork #Manufacturing #Transformation #AI #GenAI LNS Research

🔍 Manufacturing Workforce Outlook: 2023-2028 The next five years present a transformative landscape for the manufacturing workforce. Automation, AI, and evolving business models will shape the future, but people remain the core of successful operations. Here's what we foresee: 1️⃣ Increased Automation & AI Integration: Expect more tasks to be automated, especially repetitive ones. Yet, this won't replace humans but will necessitate upskilling. 2️⃣ Rise of Remote Monitoring & Operations: IoT and connected devices will enable remote machinery monitoring, meaning fewer on-site personnel but an increased demand for tech-savvy operators. 3️⃣ Focus on Soft Skills: As machines take over hard skills, human-centric skills like problem-solving, communication, and leadership will be paramount. 4️⃣ Sustainability & Eco-Manufacturing: The eco-conscious trend will amplify. Employees who understand sustainable practices will be in high demand. 5️⃣ Localized Production: Expect a push towards more local manufacturing hubs, thanks to advanced production methods and the desire for quicker supply chains. As a manufacturing company, how do you prepare? Top 5 Steps Companies Should Take Today: 1️⃣ Invest in Training & Development: Upskill employees, emphasizing both technical proficiency and soft skills. 2️⃣ Adopt & Adapt Technology: Embrace automation and AI, but ensure a balanced workforce that leverages the best of both tech and human ingenuity. 3️⃣ Promote a Culture of Continuous Learning: The future is uncertain; fostering adaptability will be key. 4️⃣ Focus on Sustainability: Train teams on eco-friendly practices and understand the evolving regulatory landscape. 5️⃣ Diversify Supply Chains: Consider local suppliers, reduce dependencies, and create resilient operations. Stay proactive and adaptive, and your manufacturing workforce will thrive in the face of change! 💡 #Manufacturing #Workforce2028 #FutureofWork #LinkedInInsights