For more than fifty years, Unilock has been a leader in the North American hardscape market, manufacturing high-performance concrete pavers and walls that transform outdoor spaces. That leadership is built upon a reputation for consistent, reliable quality—every plant, every shift, every product. With operations spread across Canada and the U.S., achieving that consistency is an ongoing challenge. To address it, Unilock has been strengthening its total quality management approach and laying the groundwork for a more data-driven future.
At the Ayr, Ontario plant, Plant Manager Dan Buckland recognized a critical barrier: quality decisions still relied heavily on paper logs, operator experience and gut feel. To advance quality performance, his team needed a digital solution that was repeatable, measurable, and capable of delivering insights—not just documentation. That’s when Unilock turned to ROO.AI.
Operating on Experience and Gut Feel
Like many manufacturers, Unilock relied on skilled operators and paper-based processes to track quality on the production frontline. Quality checks on the “wet” side of the process were entered manually into their Microsoft ERP system, but the software was not designed to provide meaningful real-time insights into quality metrics. There was no clear indication of which checks were completed, whether results were within spec, or where issues were trending.
An initial attempt to digitize quality through spreadsheets proved unmanageable. “It was crazy complicated,” Dan recalls. “Someone would have had to babysit the system constantly, and even then, the data wasn’t very useful.”
On the “dry” side, where finished stones emerge from curing, defects were simply removed and scrapped. Scrap rates were within industry norms, but there was no mechanism for learning from those defects. Operators had theories about why certain stones failed, but no way to validate them. “Everyone knew defects were happening,” Dan explains. “Everyone had an opinion. But no one had the data.”
The result: missed opportunities for cost savings, inconsistent quality improvements, and no ability to systematically prevent recurring problems.
Going From Gut Feel to Digital Clarity
Dan partnered with the ROO.AI team to digitalize quality inspections in a way that frontline operators would actually use. The new digital quality process needed to be simple, visual, and fast—otherwise adoption would fail. Leveraging ROO.AI’s unique tap-and-swipe interface, the team built inspection workflows that mirrored the molds operators saw on the production line, allowing them to record multiple stone defects in seconds.
With ROO.AI, quality data is captured instantly and automatically compiled into a Daily Quality Scorecard. Management now reviews quality performance in real time, without hunting for paperwork, re-keying data, or waiting on spreadsheets to be updated.
The results during the pilot were immediate:
“Wet” side quality scores increased by roughly 25%, stabilizing in the mid-90% range.
On the dry side, scrap % dropped by almost 50% as operators used data to adjust press recipes and eliminate recurring issues.
Instant visibility to automated reports provided daily time savings of 30 – 45 minutes of report preparation effort.
Operator adoption was good. Initial skepticism from operators quickly disappeared. “They’re very grateful that we are fixing the problem that they’re having because it’s less work for them to have to pull bad stones off the line. So it’s been good for the operators all around,” said Dan
The shift was more than technological—it marked a quality culture transformation.
When Data Surpasses Art
With ROO.AI, Unilock now has a digital backbone for a data-driven quality culture. “QA is no longer ‘did we probably check it?’” says Dan. “It’s measured, trended, and visible.” Plant management has instant visibility to quality metrics. Teams can see defects by product and press, identify exactly where problems occur, and take corrective action quickly.
Real-time insight has replaced anecdotes and assumptions. Scrap reduction now translates directly into savings that boost the bottom line, while customers benefit from more consistent product quality.
Advice for Other Manufacturers
Dan and the Unilock team piloted the ROO.AI solution in three plants. Looking back, Dan offers some practical guidance:
Start with a single pilot plant. Focusing on one location to refine the usability and workflows would have been faster, making it possible to roll out to other plants sooner.
Don’t overcollect data. During the pilot, Dan cut fields that weren’t useful. The result was faster inspections and fewer data entry errors.
Make usability a priority. “If it’s not easy, people just give up on it” Dan states.
His verdict on the ROO.AI pilot experience?
“From an idea to where it is now, it’s been very good. Everybody was very helpful along the way. Working with the company has been absolutely great.”
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
The data center construction industry sits at the intersection of rapid digitization, artificial intelligence (AI), and global demand for resilient, scalable computing. Data center construction is booming, and economist Alan Furman of Harvard estimated that along with tech investment it may be responsible for as much as 50% of US GDP growth in the last year.
As enterprises, hyperscalers, and cloud providers race to deliver capacity, data center construction companies are adapting to a broad set of emerging data center trends — from stringent data center compliance and regulations to power grid constraints, labor shortages, and sustainability pressures. To help address the implications, owners, construction company executives, contractors, and frontline leaders need a clear focus on effective planning, job site execution, and workforce performance to address the critical elements of building modern data centers
Why Data Center Construction is Different Today
AI Boom & Increasing Demand
One of the most consequential data center construction trends is the explosive growth in AI-driven data center build outs. Organizations deploying AI and AI-infrastructure are driving demand for facilities with ultra-high power density. This sharp increase not only influences data center design and infrastructure requirements but also affectsdata center construction costs, which are rising as a result.
Power Constraints & Infrastructure Delays
Power remains one of the most significant risks to project delivery. Securing utility interconnection agreements and upgrades is now a central part of data center planning, especially in regions with grid capacity limits. Delays at the utility level can ripple through project schedules and budgets, making electrical infrastructure planning a critical component of data center project management.
Sustainability & Efficiency
Today’s data centers are expected to align with data center sustainability goals. This includes improving Power Usage Effectiveness (PUE), integrating renewable energy sources, and managing water and carbon footprints. Sustainability considerations must be baked into early data center design and verified through construction and commissioning.
Complex Compliance & Regulations
With increasing scrutiny around electrical safety, fire protection, environmental impact, and energy efficiency, adherence to data center compliance and regulations is more complex than ever. Navigating local, regional, and national codes adds risk to the schedule and reinforces the need for experienced compliance professionals within project teams.
Labor & Skills Shortages
Across the industry, there’s a lack of skilled talent capable of building and commissioning high-performance data center facilities. This impacts not only hiring for construction companies but also the data center construction services ecosystem as a whole, from subcontractors to specialized technical trades.
Supply Chain Challenges
Long lead times for critical equipment — from construction equipment to facility equipment such as UPS systems, generators, and precision cooling — remain a persistent challenge. Effective logistics and procurement strategies are essential to keep projects on schedule and control data center construction costs.
Workforce Challenges in Modern Data Center Construction
Labor & Skills Shortages
Insufficient talent pools, particularly for specialized electrical and mechanical work, continue to impact delivery. This shortage emphasizes the importance of early workforce planning and strategic partnerships with training organizations.
Technical Complexity
Installing and testing redundant power paths, precision cooling, network fabrics, and building security and automation systems requires both technical know-how and rigorous execution discipline.
Trade Coordination
Complex job sites demand proactive coordination across multiple contractors and subcontractors. Without it, clashes in sequence and schedule are almost inevitable.
Safety Risk Exposure
The combination of high-energy infrastructure and tight timelines can elevate safety risk if not managed proactively. Safety must be integrated into daily operations, not treated as an administrative task.
Aggressive Schedules
Clients and developers often push aggressive delivery timelines to meet business objectives. Smart planning, risk buffers, and adaptive project management methodologies help teams deliver without compromising quality.
Best Practices that Drive Construction Execution Success and Job Site Operations that Work
Data center construction succeeds or fails at the intersection of project management discipline and frontline execution. Requiring more than conventional commercial building projects, the current AI-driven demand for data centers combines compressed schedules, state of the art high energy infrastructures, massive capital exposure, and zero-tolerance performance requirements. That means execution models must be purpose-built for speed, precision, and reliability.
The most successful data center construction companies treat project controls, workforce coordination, and quality systems as a single integrated operating system rather than disconnected functions.
1. Run Integrated, System-Driven Project Management
Best-in-class data center projects are managed around systems, not spaces. Power, cooling, controls, and network infrastructure define the true critical path — not drywall or finishes.
Effective project management practices include:
Maintaining trade-level master schedules that reflect real installation sequences
Actively managing the critical path for electrical and mechanical systems
Establishing clear escalation paths for utility, equipment, and permitting risks
Using rolling look-ahead schedules to protect commissioning milestones
Projects that do this well can adjust early when risks appear instead of discovering problems at the end of the build.
2. Use Digital Tools to Control Field Execution
Digital tools only create value when they directly support field execution. Leading teams use BIM (Building Information Modeling), construction management platforms, and connected frontline worker platforms to:
Identify and resolve clashes before materials arrive
Connect drawings, RFIs, and change orders to the actual work being performed
Track system-level progress, not just area or trade completion
Assign tasks, enable collaboration and ensure safety in the field
Enforce and document quality and regulatory compliance
The real payoff comes when the digital systems drive feed commissioning readiness. If teams know the status of every system in the project build, commissioning becomes more predictable rather than chaotic.
3. Treat QA/QC as a Production Control System
In data center construction, quality assurance and quality control are essential. QA/QC is not just paperwork — it is risk management.
Best-practice QA/QC programs include:
Well-defined quality policies, procedures and systems for documentation
Trained inspectors involved as work is performed
Digital verification of critical tasks and equipment installation
Digital inspections, photos, and digitized test records tied to each asset
Every defect that escapes early QA/QC multiplies in cost and delay during commissioning. Catching issues at the crew level is one of the most powerful ways to protect schedule and budget.
Data centers introduce unique safety risks: high-voltage electrical systems, heavy mechanical equipment, pressurized piping, and confined spaces. Leading contractors treat safety as a core operating discipline, not a compliance function.
Best practices include:
Task-based hazard analysis and energy-isolation planning
Electrical safety boundaries and lockout/tagout enforcement
Frontline safety leadership and regular safety stand-downs
Digital hazard reporting and advanced AI-powered vision safety platforms
Embedding robust safety planning and strong adherence to safety protocols directly supports worker productivity and schedule reliability.
5. Coordinate Trades Like a Production Line
Data centers are built through tightly sequenced, multi-trade workflows. Power, cooling, controls, and commissioning activities must align precisely to avoid congestion, rework, and downtime.
Best-in-class job sites use:
Weekly look-ahead schedules across all trades
Daily field coordination meetings
Clearly defined handoffs between installation and testing teams
Frontline digital tools to streamline collaboration, task assignment and handoffs
This keeps work flowing smoothly and prevents critical systems from being blocked by out-of-sequence activity.
6. Invest in Workforce Capability
Modern data center construction demands skills beyond those of traditional commercial construction. Crews must understand high-voltage systems, precision cooling, control wiring, and commissioning readiness.
Leading organizations invest in:
Targeted training aligned to data center systems
Mentorship between senior and junior technicians
Digital training tools for OTJ reference and upskilling
Certification programs tied to real job-site requirements
A capable workforce installs faster, makes fewer errors, and accelerates commissioning — protecting both schedule and costs.
7. Enforce Cross-Functional Communication
The biggest project failures rarely come from bad design — they come from misalignment between teams.
Best practices include:
Shared access to the same drawings, schedules, and system data
Regular coordination between design, construction, and commissioning teams
Tools to facilitate job site communication and collaboration in real-time
Transparent reporting of system readiness and risk
Clear communication channels across team members involved in planning and design, construction execution and management help identify issues early and ensure problems are surfaced early, when they are still manageable.
Prepare for the Drivers of Cost & Schedule Risk
Understanding what drives risk is foundational to project planning and execution:
1. Utility Interconnection and Grid Delays Securing power infrastructure and upgrades can take significantly longer than typical permitting cycles, often becoming the critical path for project delivery.
2. Equipment Lead Times Key components such as switchgear, transformers, and HVAC systems can have lead times ranging from several months to over a year, affecting both the schedule and the cost.
3. Permit and Code Compliance Multiple authorities having jurisdiction (AHJs) and overlapping regulatory frameworks increase unpredictability in scheduling and inspection cycles.
4. Labor Shortages and Rising Rates Shortages in skilled labor not only extend schedules but also escalate labor rates, directly influencing data center construction costs.
5. Design Changes Late in Construction Revisions during construction — particularly in power, cooling, or redundancy requirements — can result in rework and disruption at the site execution level.
How Digital Frontline Platforms Complete the Execution System
Even the best project plans, BIM models, and QA programs break down if the people doing the work can’t see, understand, and act on them in real time. This is where connected frontline worker platforms like ROO.AI become a force multiplier for data center construction teams. By putting work instructions, collaboration, QA checklists, safety procedures, and system status directly into the hands of construction workers, equipment operators, electricians, pipefitters, and supervisors, these platforms close the gap between planning and execution. Crews no longer rely on outdated paper prints, verbal instructions, or tribal knowledge — they work from a single source of truth that stays synchronized with project controls and design intent.
Just as importantly, frontline connected worker platforms create live feedback loops. As work is completed, tested, and inspected, that data flows back into project management, BIM, and commissioning systems. Leaders can see which systems are ready, where bottlenecks are forming, and where quality or safety risks are emerging — while there is still time to intervene. In an environment defined by aggressive schedules, complex systems, and razor-thin margins for error, digital frontline enablement isn’t a “nice to have.” It’s what turns best practices into repeatable, scalable performance across every data center build.
Ready to improve your data center construction process?
Concord Utilities Services has earned a reputation of innovation by partnering with utilities, municipalities, and equipment manufacturers to advance the future of utility technology through mass deployments of Advanced Metering Infrastructure (AMI) and utility surveys. Operating multiple projects across the United States that stretch from months to years, Concord Utilities Services has guided the installation of millions of meters and endpoints.
Operating as a trusted extension of the municipalities and utilities they serve, the Concord Utilities management team is focused on ensuring professionalism, operating efficiency, and a culture of safe practices across their field workforce. Attention to safety and standards spans all aspects of operations, including both the Concord work processes and the Concord-branded field equipment used for all projects.
Promoting Safety Training in the Field
The Concord Utilities safety program focuses on continuous safety training, along with rigorous adherence to standardized processes for regulatory compliance. Additional safety training emphasis is placed upon the unique regional and environmental safety needs of each project. As an innovator, Concord Utilities was an early adopter of technology to support field safety training, providing the workforce with access to safety training videos and documents.
However, as the company grew, Manager of Safety and Logistics, Candice Mello, recognized the need to modernize the digital tools used to promote safe operations and efficiency on the frontlines. While providing good safety content, their old solution was not flexible enough to automate the breadth of safety and operating procedures the team felt they needed to address. This led to lower engagement with the field and shifted more of the burden onto management staff to ensure adherence to standards and safety compliance. In addition, the solution could not provide the visibility and analytics across all the Concord Utilities projects that Candice needed without significant manual data manipulation outside the system.
Engaging the Field Workforce to Boost Safety
Candice and team turned to ROO.AI to modernize their safety and logistics operations and boost engagement with the field workforce. With ROO.AI, Concord Utilities was able to “stream” the existing safety training content in the ROO.AI app, providing an easier, more intuitive user experience. The team built an easily accessible library of training and, using the task management capabilities within the ROO.AI system, Candice assigned project-specific safety and skills training to individuals and teams based on a variety of factors, including skill requirements and environmental conditions for each project.
With ROO.AI they were also able to automate Job Site Safety Inspections, Incident Reporting, Vehicle Inspections and Equipment Assignments, as well as automate the process of maintaining current vehicle registrations and required project regulatory documents on site. And because all this was available through the ROO.AI mobile app, this provided a valuable “self-service” capability in the field that lessened the burden on the central office. Additionally, with all processes tracked and data in a single system, ROO.AI automated the reporting Candice used to do manually. With ROO.AI customizable dashboards, Candice has visibility for all the safety processes and compliance metrics across the various projects Concord Utilities operates.
Better Engagement Equals Better Compliance, Safety and Efficiency
Feedback from the field is positive with easier, faster inspections and in-app assignments for safety training. With ROO.AI’s built-in visibility to training and inspection completions, workers are more accountable for adherence to required procedures and compliance is improved. The system has also facilitated communications between Candice and the project teams. Instead of emails and messages, ROO.AI task management provides easy visibility to both the field and management team regarding what needs to be done and when it is completed. And having access to all the documents and SDS they need on the spot, helps the field workforce get their jobs done more safely and efficiently.
Take a Little Time to Go Faster
The ROO.AI Concierge team works closely with every customer to create the customized training workflows, inspections and analytics that will meet the business’s unique requirements, minimizing the burden on the customer to build forms or reports. After implementing ROO.AI across all their project teams, Candice offers this advice to companies adopting ROO.AI. She recommends identifying a point person to lead the project and specific team members in the field to learn the system and be available locally as leads for the workers on site. She also recommends spending some time upfront in the project to understand how the business’s terminology and needs are represented in the ROO.AI system. Once you have a handle on that mapping, she says, you make progress very quickly.
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
The manufacturing industry is facing a significant skills gap that threatens productivity, quality and overall industry growth. Three key factors driving this gap are the displacements of experienced workers during the pandemic, the accelerating retirement of experienced workers and the increasing complexity of modern manufacturing equipment and processes. As senior workers leave the workforce, they take with them decades of accumulated knowledge. Meanwhile, the new workers entering the field come from a demographic that expects digital tools that can assist them with daily tasks, making traditional training methods less effective and extending onboarding time.
Connected worker solutions provide a critical bridge for this gap by leveraging digital technologies to enhance workforce capabilities both during the onboarding process and as needed to assist and upskill the workforce during daily operations. Here are eight ways connected worker solutions are transforming manufacturing by addressing the skills gap.
1. Accelerating Onboarding of New Hires
Onboarding new employees has traditionally relied upon classroom training or shadowing assignments which have been time-consuming and costly in terms of manpower. Connected worker solutions streamline this process by providing easier access to self-guided training combined with on-the-spot digital work instructions. Onboarding programs leveraging connected worker solutions supplement initial training with interactive digital training modules, and may also include augmented reality (AR) or virtual reality (VR) simulations. These tools enable new hires to learn faster by offering more flexible, engaging access to training and hands-on experiences in a controlled, risk-free environment. As a result, manufacturers can reduce onboarding time and ensure workers are productive sooner.
2. Delivering On-the-Spot Work Guidance
Rather than relying on paper manuals or long periods of time shadowing senior workers for instructions, frontline workers can access real-time digital guidance through mobile devices, wearables, or smart glasses. QR codes or IoT-enabled sensors can trigger step-by-step instructions at the point of need, reducing errors and increasing efficiency. This on-demand guidance ensures workers have immediate access to the information required to perform their tasks correctly.
3. Fostering Skills Development with On-Demand Training
In today’s fast-paced environment, continuous learning is essential. Connected worker platforms provide microlearning modules, video tutorials, and interactive guides that workers can access anytime. These tools support ongoing skills development and reinforce best practices without requiring time away from work for traditional classroom training. Supervisors can more easily and effectively mentor workers by encouraging or assigning the workers to engage in specific training modules. Gamification elements, such as progress tracking and achievement badges, further enhance worker engagement and retention. In addition, many solutions can provide visibility to management of worker course completions and skills attainment, enabling more effective application of workforce resources.
4. Automating Repetitive Data Collection Tasks
Manual data collection is prone to errors and inefficiencies, both on the part of workers who often see these tasks as extra work, and on the part of administrative staff who are needed to data enter hurriedly scribbled paper checklists and data forms. Digital tools can simplify the collection of data on the frontline and automate the capture of that data, reducing paperwork and freeing up workers to focus on higher-value tasks. Connected worker solutions may also leverage IoT-enabled devices to automatically log operational or equipment performance metrics, completely eliminating any need for worker input. Automated data collection also ensures more accurate and timely reporting, leading to better decision-making and improved compliance.
5. Providing Easier, Faster Communication and Collaboration
Effective communication is crucial in manufacturing environments. Connected worker software offers instant messaging and collaboration platforms that enable workers to communicate more easily. Some connected worker platforms also offer alerts, notifications, reminders and task assignments, further improving communications and streamlining daily work tasks. These tools empower frontline workers to connect with remote experts, supervisors, or team members to highlight and resolve issues quickly. Digital shift handover logs ensure smooth transitions between shifts and minimize knowledge loss.
6. Enabling a Safer Workplace Across All Skill Levels
Worker safety is a top priority, and connected worker solutions can play a significant role in preventing accidents that may occur due to lack of experience. Digital safety checks can help workers spot and quickly report potential risks. Wearable sensors can monitor worker conditions, such as fatigue levels or exposure to hazardous substances, and issue real-time alerts when safety thresholds are exceeded. Automated notifications for potential risks—such as equipment malfunctions or environmental hazards—help ensure a safer work environment across all skill levels.
7. Supporting Knowledge Retention and Transfer
As experienced workers retire, capturing and retaining their knowledge is crucial. Digital repositories created through connected worker messaging, work instructions and training allow workers to contribute to the documentation of best practices, troubleshooting steps, and operational insights for future reference. AI-powered search functions make retrieving this information quick and efficient, ensuring that valuable expertise remains accessible to new generations of workers.
8. Enhancing Quality Control and Compliance
Maintaining consistent product quality is essential in manufacturing. Connected worker solutions can integrate digital inspection tools and automated checklists to help workers identify defects in real time. Digitalized quality processes enable easier, faster quality checks by both workers and quality specialists. Digitalized defect data delivers instant visibility to production quality, enabling faster recognition of production issues and quicker response with corrective actions. Some connected worker platforms can also create a closed loop system for engaging production teams to address and correct defects as they are identified with work notifications and tasks automatically generated by the connected worker solution. These technologies can help reduce the likelihood of human error, facilitate compliance to quality processes, and as a result, improve overall product quality.
Leveraging Technology To Address A Changing Workforce Landscape
Brought on by the displacement of skilled workers during the pandemic, the increase in retirement rates for experienced workers and a tight labor market, the skills gap in manufacturing poses significant challenges. Traditional training and mentoring methods are no longer capable of effectively overcoming the skills gaps, but connected worker solutions offer a powerful way to address them. By leveraging digital tools to accelerate onboarding, provide real-time guidance, support continuous learning, and enhance safety and quality, manufacturers can future-proof their workforce. Investing in connected worker solutions not only improves productivity but also creates a more engaged, skilled, and adaptable workforce—essential for success in the evolving manufacturing landscape.
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
Discover the connected worker: its definition, technologies, benefits, real-world use cases, and how to choose the right solution for your organization.
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
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.
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
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.
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
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.
Solution: The key is that the digital safety system should be designed to enhance the user’s ability to perform safety reporting or receive safety notifications without requiring them to deviate significantly from their usual routines. Digitalization can greatly improve accessibility to real time safety reporting as compared to paper, but both process and physical issues should be taken into consideration. Engage with frontline workers during the design and implementation phases to understand their workflows and ensure that the system aligns with their needs. Thought should be given to device access, badge and QR code scanning to simplify access and shorten navigation to appropriate digital safety workflows. Look for technology platforms that make safety data readily available to frontline teams in context and incorporate alerts or notifications.
Avoid Overly Complex Processes
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.
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
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.
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
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.
Author
Stephen Zocchi
Enabling the frontline workforce by digitalizing human powered process
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