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Top Mistakes To Avoid When Digitalizing 
New Worker Onboarding


Rapid and effective onboarding of new workers has become a ‘must-have’ capability for companies as they rebuild post-pandemic workforce skill sets. In today’s everything-digital age, digitalizing onboarding offers the flexibility and accessibility that traditional classroom and paper-based methods lack. However, like any tool, digital training can be ineffective if not implemented correctly. In addition, many companies find that online courseware, as enabled by most computerized Learning Management Systems (LMS), is not enough for the new workforce demographics. Here are some of the most common pitfalls for the digitalization of new worker onboarding:

1. Overloading Content

Digital training offers the convenience 
of delivering vast amounts of information more easily. To avoid overwhelming new workers with too much content at once, which can make 
it difficult for workers to retain essential information, break down training into manageable modules and use microlearning techniques to keep content digestible.

2. Ignoring Engagement

Digital courseware often lacks the interactive elements that make classroom training engaging. Relying solely on presentations or text-heavy modules can result in disengagement. Videos help but are not a panacea. To maintain interest, incorporate multiple elements into training and include interactive tools such as quizzes, simulations, and interactive content.

3. Lack of Personalization

One of the most significant mistakes is treating digital training as a one-size-fits-all solution. Each new hire has unique skills, experiences, and learning styles, particularly now that workforce demographics may span three generations. Failing to personalize the training experience can lead to disengagement and slower ramp-up. Consider offering tailored learning paths that allow workers to focus on areas where they need to upskill while bypassing content they already know.


4. Inadequate Assessment and Feedback

Another common mistake is not providing adequate assessment and feedback mechanisms. Proper evaluation makes it easier to gauge how well workers understand the material or identify areas where they need more support. Include regular assessments, such as quizzes or assignments, and provide timely feedback to help workers track their progress and address any learning gaps.


5. Failing to Integrate with Company Culture

While the transfer of knowledge is a primary goal of onboarding, failing to integrate cultural elements into the training can leave new hires feeling disconnected. Include modules on company values, mission, and expected behaviors to help employees understand and embrace the organizational culture.

Digitalize 
Onboarding 
With Best Practices In Mind

Despite potential challenges, digitalizing the onboarding process is undoubtedly a necessity for companies rebuilding their workforce, whether that is due to skills gaps from the attrition of experienced workers or the need to expand the workforce to drive growth. According to a McKinsey study, companies that invested in frontline training, and development saw double revenue growth rates and 37% less worker attrition than other companies that were also reviewed in the study. Digital training is also becoming table stakes as companies compete for workers who are accustomed to doing everything on a mobile device.

Learning In The Flow Of Work

Digital training courseware is a powerful tool for onboarding new workers, but its effectiveness depends 
on avoiding common pitfalls. Following best practices like incorporating microlearning, building engaging and interactive content, personalization and feedback, and digitalizing onboarding training can help companies successfully transform their onboarding programs. 
At ROO.AI, we believe that the digitalization of onboarding is just the first step.

Stephen Zocchi
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

Digital Transformation in Quality Management

Mistakes that Cause Frontline Workers to Resist Adopting Digital Quality Inspection Management

Implementing a digital quality inspection system can revolutionize a manufacturing organization’s approach to maintaining high-quality standards. It offers real-time insights, enhanced data accuracy, and boosts productivity for both quality and production teams. However, the success of digital quality control hinges on its adoption by frontline workers—the people who will use it daily.

Unfortunately, there is a common disconnect between the needs that drive projects and the outcomes when digitalizing frontline processes as highlighted by research done by Deloitte and Forrester. The need for frontline digitalization is great, with only 23% of frontline workers stating they have the technology they require to be productive. However, almost 70% of digitalization project failures are due to poor user adoption, especially for frontline digitalization projects.


With digital quality control projects, it is critical to emphasize how frontline workers will interact with the system and its impact on their typical flow of work. For the most part, digital systems are designed for office workers, with text-heavy digital forms and checklists that are not intuitive for frontline workers. Several common issues arise from these office-centric interfaces and related implementation practices that can undermine adoption and lead to frustration, inefficiency, and, ultimately, the system’s failure.

Poor Usability & Complex Data Entry


A system that is difficult to navigate or requires cumbersome data entry can quickly become a source of frustration for its users. Poor usability directly affects workers’ efficiency and accuracy, slowing down inspections, increasing the likelihood of mistakes, and ultimately causing workers to abandon the system altogether. If workers feel the system is making their jobs harder, their frustration will likely lead them to revert to manual methods, undermining the benefits of the digital system.

Solution: To avoid this pitfall, prioritize user-friendly design during the selection of the digital technology, and the design and implementation of the system. The interface should be clean, simple, and easy to navigate, even for those who may not be tech-savvy. Data entry processes should be streamlined with features like drop-down menus, multi-choice or multi-select answers, autofill options, and error-checking prompts to reduce the burden on workers and ensure data accuracy.

Lack of Personalization


Another common mistake when implementing a digital quality inspection system is taking a one-size-fits-all approach. Different organizational roles have different needs; the same applies to workers with differing experience levels. A system that does not allow for personalization adds barriers to adoption and consistency of use. Experienced workers will want the fastest, fewest clicks possible, whereas new workers may need more detailed guidance to ensure proper adherence to the process and accurate data capture.

Stephen Zocchi
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

Ensure Frontline Workers Adopt Digital Safety Management

Implementing a digital safety solution is a significant step toward enhancing workplace safety, improving compliance, and reducing risks. A recent survey of frontline workers in manufacturing and warehouse jobs that was cited in Safety + Health Magazine, showed that over 50% of workers spotted 1-2 safety hazards per week. Furthermore, rapid response to hazards reports and real time communication with team members about safety hazards were the top two most recommended solutions to improving workplace safety.

Connected worker platforms that can digitalize safety reporting, training and visibility to corrective actions directly address the safety improvements that frontline workers prioritize. However, the success of such a system hinges on its adoption by the very individuals who will interact with it daily – frontline workers. If the system is not embraced by these workers, its effectiveness is severely compromised, leading to safety gaps and operational inefficiencies. To ensure successful adoption, it’s crucial to consider these implementation best practices.

Focus On Usability

A system that is difficult to navigate or requires cumbersome data entry can quickly become a source of frustration for its users. If the interface is not intuitive, workers may struggle to complete tasks efficiently, leading to errors or omissions in safety procedures. If hazard reporting is not quick and easy, workers may opt to delay using the digital solution increasing workplace safety risks. Over time, this frustration can result in a reluctance to use the system at all, undermining the safety protocols it was designed to enforce.

Solution: To improve usability, prioritize user-friendly design during the selection of the digital technology, and the design and implementation of the system. The interface should be clean, simple, and easy to navigate, even for those who may not be tech-savvy. Conduct usability testing with actual frontline workers during the evaluation, design and implementation phases to identify and address any potential issues. Data entry processes should be streamlined with features like drop-down menus, multi-choice or multi-select answers, autofill options, and error-checking prompts to reduce the burden on workers and ensure data accuracy.

Align Safety With Daily Flow Of Work

When the system does not align with the natural flow of work, it can create bottlenecks and inefficiencies. Workers may feel that the system is an additional burden rather than a tool designed to help them, which will slow adoption. Particularly when it comes to safety inspections and training, the workers should not be forced to alter standard processes that are proven to be effective, or to disrupt their flow of work to capture safety issues or benefit from safety notifications.

Stephen Zocchi
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

How Digital Technologies Help Manufacturing Attract And Retain Workers

The manufacturing industry is facing a pressing labor shortage, with many companies struggling to attract and retain skilled frontline workers. Several factors contribute to this challenge, including an aging workforce, increased competition from other industries, limited growth of vocational training and the perceived unattractiveness of the job opportunities available to new workers. Digital technologies, like frontline connected worker platforms, are emerging as powerful tools for manufacturing companies to help attract, develop and retain workers. These digital tools, which enhance communication, streamline processes and data capture, provide on-the-spot training, and facilitate real-time knowledge, can also enhance the onboarding experience, improve job satisfaction, and offer career development opportunities as they make the workplace more efficient and safer for employees.

Attracting a New Generation of Manufacturing Workers

A benefit of digital connected worker technologies in manufacturing is its use in the recruitment process for workforce talent, particularly with younger workers who have grown up with technology and expect similar tools in the workplace. These digital natives are drawn to employers who invest in innovation and offer cutting-edge technologies that streamline work. Manufacturing companies that implement smart devices, augmented reality (AR), and mobile applications for tasks like work instruction, quality inspection, and equipment maintenance gain a competitive advantage in attracting the best talent.

Improving the Onboarding Experience

Onboarding can be a daunting process for new hires in manufacturing, where complex machinery and processes often require long training periods. Traditionally, onboarding has been time-consuming and resource-intensive, relying on paper manuals and in-person mentorship. According to studies by ISG Research, it typically takes six to nine months to fully onboard a new employee. However, research showed that with the use of digital tools, that timeframe can be reduced to three to six months, helping manufacturers get new hires up to speed more quickly

Connected worker apps and digital work instructions provide step-by-step guides that employees can access in real-time, making it easier for them to learn tasks quickly, follow standardized procedures and reduce the likelihood of errors. Interactive digital tools, such as augmented reality (AR) and virtual reality (VR), allow new employees to learn by immersing themselves in realistic, simulated environments. Deloitte research showed that roughly 50% of workers preferred access to training on the spot over standard classroom training, not only accelerating the onboarding process but also improving the experience which increases retention.

Enhancing Job Satisfaction

One of the key ways digital technologies improve retention is by empowering employees to perform their tasks more effectively. A common challenge for frontline workers is dealing with repetitive tasks using antiquated tools and processes. A survey by Microsoft showed that 36% of manufacturing workers felt that they did not have the right technology tools to do their job effectively. Digital technologies, like connected worker platforms, automate data collection and provide workers with real-time data, visual instructions, and safety alerts, enabling them to make faster and more informed decisions. Job satisfaction is crucial to retaining frontline workers, and technology can play a significant role in making them more effective and their jobs more fulfilling

Improving Safety in the Manufacturing Workplace

Safety is a top priority in any manufacturing environment and can be a top factor when workers are considering joining or remaining with a manufacturer’s workforce. Digital technologies can greatly enhance workplace safety. These tools can provide real-time alerts about equipment malfunctions or hazardous conditions, ensuring that workers are immediately informed of any risks. Digital checklists help facilitate compliance with safety protocols, while remote assistance allows supervisors to provide immediate guidance to workers. Wearable devices can provide real-time data on environmental conditions, such as air quality or warn of proximity to hazards, and can also monitor health indicators, such as heart rate and body temperature to ensure safety thresholds are not exceeded. By fostering a safer work environment, manufacturers not only protect their workers but also boost overall morale and job satisfaction.

Expanding Career Development Opportunities

Frontline workers in manufacturing, especially younger generations, increasingly value career growth and continuous learning. Digital technology enables manufacturers to offer training and development opportunities beyond the onboarding period that increase employees’ skills and open up new career paths.

Digital platforms provide workers with the flexibility to access training on-demand, allowing them to develop new competencies at their own pace. Technologies such as AR and VR can also be used for more advanced training, teaching workers how to operate complex machinery or repair equipment in virtual environments. This enables frontline workers to learn new skills without the risks associated with training on live equipment. By offering these upskilling opportunities, manufacturers can promote skills development and bridge the skills gaps left by retiring workers, and enable the professional development that helps companies retain workers by offering pathways for career advancement.

Gaining a Digital Advantage For Talent Management

Attracting and retaining frontline workers in manufacturing requires more than just competitive wages. By adopting frontline digital technologies, manufacturers gain a strategic advantage in attracting and retaining skilled workers by offering a more appealing and supportive work environment that enhances job satisfaction, provides career development opportunities and improves safety. Embracing these technologies not only helps manufacturers stay competitive, but also ensures that their workforce remains engaged, skilled, and committed to long-term growth.

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Stephen Zocchi
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Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

Why Manufacturing Needs to Combine Talent Strategies with Productivity Enhancement

The U.S. manufacturing sector is currently undergoing a boom, thanks to a strong economy and significant federal investment. In 2023 alone, the sector received $196 billion in federal funding for manufacturing construction, marking a 143% increase since 2019. This capital infusion, which continued into 2024 with an additional $32 billion, has been bolstered by programs like the $39 billion CHIPS Act for semiconductor manufacturing. However, for this capital influx to yield substantial economic benefits, manufacturing companies must address the critical workforce shortages and skills gaps that have increased since the pandemic.

Skills Shortages: A Drag on Growth

The manufacturing industry faces a dual challenge: significant labor shortages and a widening skills gap. As of January 2024, the U.S. Bureau of Labor Statistics reported 622,000 unfilled manufacturing job openings across the country. This shortage comes at a time when the overall labor force participation rate has fallen below 63%, a steep drop from the 67% rates of the 1990s. Despite efforts to rehire many of the 1.4 million workers laid off during the pandemic, manufacturing companies are struggling to fill roles, with many reporting high turnover and challenges in retaining new hires.

The workforce shortage is exacerbated by several factors, including an aging workforce, challenges attracting younger workers into manufacturing, and migration of experienced workers into other sectors after the pandemic. This is not a short-term issue; according to McKinsey, the industry could face a shortage of 1.5 to 2.5 million workers by 2030. As a result, it is becoming clear that manufacturers must expand the focus of workforce management to include advancing productivity per worker.

Supplementing Talent Strategies with Frontline Technology

Given the labor market challenges, adopting digital solutions on the frontline can be an effective component of implementing new talent strategies to attract, develop, and retain workers. Traditional methods of onboarding and training often take months for new workers to ramp up completely. With an excess of unfilled positions, accelerating time to productivity for frontline workers is critical.

Skills gaps that have emerged within the existing workforce as experienced workers leave the industry are also a drain on productivity. In addition, investments in digitalizing manufacturing operations add further pressure to reskill and upskill the workforce to operate the new advanced machinery and digital systems more effectively.

Another essential area of focus for talent strategy is addressing the expectations of younger workers regarding their work environment and resources. Manufacturing companies are facing mismatched expectations with new generations of talent, who have grown accustomed to using digital systems for every aspect of their lives. Supplementing talent strategies with frontline technologies that boost productivity can benefit manufacturers in several ways.

Accelerated Onboarding

Compressing the time to productivity for new workers is a major benefit of blending frontline technology with talent strategies. According to studies by ISG Research, organizations report that it typically takes six to nine months to fully onboard a new employee. However, with the use of digital tools, that timeframe can be reduced to three to six months, helping manufacturers get new hires up to speed more quickly. Digital tools can be used to provide new workers with easy access to training materials, personalized for their roles and levels of experience. A strong onboarding program not only improved retention by as much as 82%, but also improved productivity by 70% according to research done by Brandon Hall Group.

Upskilling and Ensuring Standardization

In addition to absorbing new workers, today’s manufacturing workforces are also seeing workers with less experience occupying roles that were once filled by more experienced personnel. Research done by SHRM reported that 55% of workers felt they did not have the training they needed to do their jobs effectively. Digital frontline technologies are a powerful addition to manufacturer talent management strategies for upskilling and reskilling the workforce.

Digital automation of processes such as inspections can reduce process time by up to 70% by using mobile devices to reduce data entry and paperwork according to PWC studies. Digital work instruction can provide on the spot guidance and embed training to ensure that standard processes are followed quickly and accurately. The same PWC study showed productivity increases of up to 30% from digitalizing work processes. Deloitte research into training showed that roughly 50% of workers preferred these on-the-spot micro-learning injections over standard classroom training.

Reducing Frustration and Non-Productive Time

Delays are not only productivity killers; they are also a source of frustration for frontline workers and can affect workforce retention. Frontline workers in over 50% of companies do not have easy access to company digital devices for communications, yet 62% of companies report that their workers need to access digital information or communications at least 5 times every 2 hours according to ISG Research. Not having the right technology tools to do their job effectively is a sentiment echoed by 36% of manufacturing workers according to a survey done by Microsoft. Not only can connecting workers with easy access to digital devices reduce the lost time and frustration that workers are experiencing, but it can enhance the ability of frontline teams to collaborate more quickly to address work and safe issues to further boost productivity.

A More Engaging and Attractive Work Experience

Manufacturing is often seen by younger workers as less appealing and exciting than other industries. Competition for these younger workers is fierce, and the talent strategies for manufacturers need to gear up to attract these workers. Frontline digital technologies help present a more modern, forward looking work environment to prospective employees. In the Microsoft study previously cited, 63% of frontline workers said they were excited by the work opportunities that new technologies could bring to their jobs and 46% valued receiving new technology tools over wellness and health benefits for improving their work experience.

Aligning Talent Strategies with Productivity Boosting Technology

As manufacturing companies begin to implement new talent strategies to attract, develop and retain workers, they should expand their focus to consider the integration of technology into their strategies. Frontline worker-specific technologies, such as digital automation and assistance on mobile devices, augmented reality (AR) systems, wearable technologies and AI, are transforming how work is performed on the factory floor. These tools help streamline operations, reduce errors, improve safety and ensure that tasks are completed more efficiently.

With U.S. manufacturing entering a new era of growth, companies must adapt to the realities of the limited availability of skilled labor and an evolving workforce demographic. By combining productivity-enhancing technologies with forward-thinking talent strategies, manufacturers are better prepared to overcome labor shortages and skills gaps. The integration of digital tools is crucial for improving both frontline worker training, as well as, productivity and operational efficiency, enabling the manufacturing sector to capitalize on its current momentum and ensure sustainable growth in the years to come.

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Stephen Zocchi
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Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

What is 5S Audit?

The 5S framework is a systematic approach primarily used in the manufacturing sector to create organized, clean, and efficient workspaces. This method promotes a culture of continuous improvement that enhances productivity and safety. The 5S audit checklist serves as a vital tool in this process, helping businesses maintain the discipline needed to ensure each element of 5S is properly implemented.

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Stephen Zocchi
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Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

When Training and Work Become One

With businesses facing increasing skills shortages in a tight labor market, the need for effective training and development programs for workers has never been more critical. Traditional approaches such as paper-based training binders or computerized Learning Management Systems (LMS) have been the backbone of corporate training initiatives to date. However, as skills gaps widen and job requirements become more demanding, there is a growing recognition of the limitations of traditional classroom and online learning approaches.

Learning in the flow of work

Microlearning, an approach to delivering bite-sized learning content in short, focused bursts, has caught the attention of most training teams. Its brevity makes it highly accessible and convenient, fitting the modern worker’s shorter attention span. Secondly, microlearning enhances retention and comprehension by presenting information in digestible chunks, allowing learners to absorb and apply knowledge more effectively. A study from Training Magazine found that organizations using microlearning saw a 20% increase in employee productivity and a 23% increase in employee satisfaction.

With today’s mobile digital technologies, microlearning platforms or microlearning apps can deliver content on demand and personalized based on the process, worker activity or experience level. Josh Bersin, a Deloitte Partner and head of their corporate learning practice, wrote an interesting article where he coined the phrase “Learning in the flow of work.”  He sees the future of training as fusing microlearning apps into the digital platforms that workers use to get their jobs done. And he points to studies showing that 49% of workers want to consume training at the point of need.

When training and work become one

Reimaging training as a component of the work process not only represents a game-changer in the realm of workforce training and development, but also becomes a driver to bridge the growing skills gaps and boost worker productivity and quality. By weaving training  into daily work processes and procedures, organizations can see their training efforts improve in several key areas:

1. Contextual and Situational Relevance

Integrating training into work instruction ensures that learning experiences are directly relevant to worker’s day-to-day responsibilities and tasks. By embedding training content within the context of actual job functions, the workforce can immediately address knowledge and skills gaps at the point of need.

2. Efficient Use of Time and Resources

Digital access to training optimizes the use of time and resources by minimizing disruptions to workflow and productivity. Instant access to training and information when needed maximizes efficiency and minimizes downtime. Instead of allocating separate time slots for training sessions, employees can seamlessly transition between learning and work tasks.

3. Interactive and Engaging Learning Experiences

Digitalized access and embedded microlearning enable more interactive and engaging learning experiences in an on-demand style. Training can engage workers with multimedia and interactivity to deliver a hands-on experience that enhances retention and comprehension, and makes learning more enjoyable and memorable.

It starts by digitalizing the frontline

With increasing skilled labor scarcity and growing job complexity, it is clear that the tools of the frontline workforce need to be modernized. The good news is that today workers are more comfortable with digital apps on mobile devices, and the next generation of frontline workers expect these types of resources to be available to them on the job. Particularly in manufacturing and field services, where replacing paper with mobile devices to enable more efficient inspections, work instruction and maintenance, the opportunity to blend training into work processes with microlearning platforms is compelling. Empowering frontline workers to access training on demand drives productivity and quality. Training in the flow of work saves on time away from the job and makes critical information available at the point of need. Making training more accessible, engaging and relevant builds a work culture of continuous learning that benefits both the workforce and the business.

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Stephen Zocchi
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Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

Ensuring Safety and Compliance with Digitalized Lock Out – Tag Out Processes

In industrial settings, where machinery and equipment pose inherent hazards, implementing robust lockout-tagout (LOTO) procedures is crucial for safeguarding the well-being of workers. In the realm of industrial safety, the lockout-tagout (LOTO) process stands as a cornerstone for preventing accidents during equipment maintenance and servicing. To optimize safety and compliance, organizations must adhere to best practices for executing LOTO processes effectively. With the advent of digital work instruction solutions on mobile devices, LOTO best practices can be more effectively enforced in several ways.

Enforcing Standardization

Digitalizing LOTO processes allows for the standardization of safety protocols, minimizing human error and ensuring consistency. Enabling workers with digital tools can enforce predefined workflows and procedures, guiding workers through the steps required to safely isolate energy sources and apply lockout devices. By standardizing LOTO procedures, organizations can mitigate the risk of procedural deviations that can increase the risk of accidents.

Continuous Training and Education

Ensuring ongoing training and education on LOTO procedures is crucial to reinforce knowledge and skills. Modern digital frontline platforms such as ROO.AI offer the opportunity to embed training and safety reminders in the flow of work, providing the workforce with in-context learning opportunities. Along with offering easier access to safety training on demand, digital frontline tools can facilitate improved toolbox talks, and scenario-based training exercises to help reinforce the importance of LOTO compliance and safety-consciousness.

Enhanced Documentation and Compliance

Digitalization facilitates comprehensive documentation of LOTO procedures, improving monitoring and compliance with regulatory requirements. Digital lockout-tagout workflows enable organizations to automatically capture equipment information, procedural verification using images and video, and generate digital audit trails of LOTO activities. This digitized documentation not only enhances accountability but also simplifies regulatory reporting and compliance assessments, reducing the risk of non-compliance penalties and fines.

Digitalize LOTO Best Practices

Digitalizing lockout-tagout processes offers a transformative approach to enhancing workplace safety, efficiency, and compliance. By leveraging digital solutions to automate procedures, reinforce safety training and improve documentation, organizations can elevate safety standards, reduce risks, and foster a culture of safety excellence. As manufacturers strive to embrace digital transformation initiatives, digitalizing LOTO processes emerges as a critical enabler for achieving safety objectives and safeguarding employee well-being in industrial environments.

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Stephen Zocchi
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Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

Manufacturing Safety Audit Checklist

Download our free PDF Safety Audit Form, or Get a Live Demo to discover how we incorporated this checklist into an easier, faster mobile app with visual assistance to guide the inspection. Customize inspections and work instructions to your exact equipment and manufacturing processes to boost safety and compliance with regulations.

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Stephen Zocchi
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Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process

Warehouse Safety Inspection Checklist

Download our free PDF warehouse inspection form or get a live demo to discover how we incorporated this checklist into an easier, faster mobile app with visual inspection assistance.

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Stephen Zocchi
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Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process