Navigating the Path to Workforce Optimization

Summary

The primary goal of industry digital transformation for operational technologies (OT) teams is workforce optimization, according to a recent ABI Research study, with their key focus on improving knowledge retention and team collaboration and communication. When information technology (IT) professionals also prioritize workforce optimization, improving knowledge retention and quality levels are critical topics for them.  
 
But it’s as teams begin implementing Industry 4.0 use cases, such as predictive maintenance, to achieve these goals, that they find a lack of expertise and the difference in IT and OT approach is holding back progress. It’s vital then, as OT teams plan to connect assets to support use cases, that they align with IT to identify the infrastructure investments required to support them.

How private wireless plus edge computing will support the Industry 4.0 evolution

The research found that in companies across all vertical segments, including chemicals, fabricated metals, mining, ports and logistics, heavy machinery manufacturers, electronics and appliances, and petroleum, IT has prioritized the deployments of technology such as Wi-Fi and mesh Wi-Fi networks to support a better-connected workforce with smartphones and other devices.

While some have also explored wireless campus technologies, few are investigating the use of edge computing. That isn’t surprising given that many are yet to connect equipment to the internet, but as they begin doing so, the limitations of Wi-Fi will become apparent.

For example, while Wi-Fi may connect people and support applications that aren’t reliant on low latency, such as email, we all know how Wi-Fi is impacted in high-traffic locations.

As more sensors are connected to machines to allow teams to access health readings or to robots to enable automation, the Wi-Fi mesh network will begin to feel the strain. Add to that, the fact that Wi-Fi signals can be impeded by metal structures, and connectivity may be severely impacted in certain environments, such as factory floors. Any delays to the transmission of data such as machine health could result in costly machine repairs and productivity losses.

So, as companies investigate the use of operational intelligence to optimize productivity and quality, they should also evolve IT infrastructure using technologies such as private wireless campus networks.

Using 4G and 5G private wireless, they can benefit from standards-based secure, robust networks that will support the massive connectivity demands of machines, people and sensors. Teams will also benefit from dramatically lower latency compared to Wi-Fi to implement capabilities that rely on the real-time transfer of data, such as predictive maintenance for enhanced machine performance and productivity.

With this robust private wireless connectivity in place, OT teams will have the flexibility to explore other Industry 4.0 workforce optimization use cases. They can, for example, increase automation to benefit from greater accuracy for repetitive tasks by connecting more autonomous mobile robots (AMRs). With the ability to leverage real-time situational awareness and data analytics, AMRs will be able to traverse the factory floor safely and efficiently alongside other robots and people.

Additionally, inspections of hazardous areas can be improved using drones connected over the private wireless network to transmit videos to teams. Perhaps unsurprisingly, given safety concerns, the research found that the petroleum industry is ahead of others in terms of the deployment of private 4G networks as well as connected drones and digital twins, which provide a virtual representation of a facility.
 

An evolution toward the metaverse relies on industrial edge

As digital transformation needs evolve, OT teams may want to capitalize on metaverse-related capabilities such as augmented, virtual and mixed reality (AR, VR and MR) applications. These offer clear benefits for user training, product development and more. For example, employees can access virtual training on equipment in simulated high-risk environments, without being placed at risk, or collaborate virtually to accelerate new product introduction.

For some advanced Industry 4.0 and metaverse-related use cases to be implemented successfully, the IT infrastructure must again evolve to incorporate an industrial edge, allowing data to be processed on-premises
and consumed by applications in real-time.

Zero fault manufacturing, for example, will rely on this. This uses connected cameras, object identification applications and machine learning to automate product quality monitoring, with any anomalies detected triggering alerts that halt machines and notify maintenance. Any delay as data travels to the public cloud to be processed will impact these capabilities.
 

Evolve IT and OT seamlessly in an as-a-service model

The ABI Research report uncovered examples of how digitalization was being impacted by lack of IT/OT alignment across various industries. For example, lack of software application investment is causing heavy machinery manufacturers to lag other industries in connecting and optimizing asset performance and in eliminating paper-based operations. Mining companies could benefit from equipment digitalization, to reduce waste, enhance operational accuracy and better protect themselves against external shocks.

It’s clear that without investment in IT, growth in OT use cases over time will overload the infrastructure, while investing too early can mean spare capacity will waste budget. So, to ensure IT and OT investments and visions are aligned, industries should partner with providers that offer private wireless connectivity in an as-a-service model.

By choosing a robust platform that incorporates Wi-Fi and industrial edge, teams can evolve their infrastructure as their use-case needs dictate to achieve workforce optimization in the most efficient and effective way possible.