Unlocking Potential: The Connected Workforce Explained

Companies are improving efficiency on the plant floor by making human-machine interfaces (HMIs) movable along the production line. This allows operators to easily access controls from different points along the line. Further, tablet-like portable HMIs enable operators to manage a machine without being physically next to it. This portability enhances convenience and allows for greater flexibility in monitoring and controlling machinery.

Another common adjustment to HMIs is the introduction of multiple language options. Rather than just English, many are now offering various language options to increase accessibility and expand the potential pool of available workers.

Machine builders are also simplifying HMI user interfaces, incorporating more pictures and app-style icons. This makes it easier for new operators to learn and reduces training time, helping to get the line running quickly. More machines are also now equipped to show visuals of the machine parts that may be down. This speeds up the troubleshooting process to reduce downtime, as operators can easily identify which part of the machine is experiencing an issue.

Missouri-based Logboat Brewing used an automated control system including HMI systems with mirrored displays to streamline communication across the plant and improve efficiency. For an example of connected HMI systems in action, read the full story at ProFood World.

Effective use of data for predictive maintenance

One strategy that Business Intelligence researchers say continues to gain traction in the packaging sector is predictive maintenance. Predictive maintenance differs from preventative maintenance, which is currently the most common of the two. Preventative maintenance involves scheduled servicing, but it may not always be timely or necessary. In contrast, predictive maintenance uses data-driven insights to anticipate when maintenance should be performed, optimizing deployment of labor.

Predictive maintenance allows operators to know in advance when a part is likely to fail. It can reduce the risk of unexpected stoppages, and streamline maintenance by ensuring replacement parts are in stock or ordering new parts before a failure occurs.

While predictive maintenance is still emerging in packaging, it has potential to significantly reduce downtime and alleviate some of the labor demands on machine technicians.

How AI could support workers

With the rapid advancements in AI technology, there is growing excitement and interest in how these innovations could support the packaging workforce.

AI could help line workers to better understand and remedy machine inefficiencies to improve OEE.onuma Inthapong via Getty ImagesMachine operators can use AI assistants for time-consuming tasks like data entry and coding, according to PMMI Business Intelligence’s 2024 report, “The AI Advantage in Equipment: BoostingPerformance and Bridging Skills Gaps.” This increases the speed at which projects can be completed, freeing up time for staff to focus on other valuable tasks.

AI could also be a solution to close skills gaps. With a high turnover of roles (especially among maintenance staff and machine operators), the optimized training provided in connected worker platforms can ensure that all employees are receiving the highest quality training available. AI assistants and generative AI predictive maintenance solutions allow users to ask questions regarding issues they are having on machines, further enabling members of staff to upskill independently and reduce the risk of human error.

Digital twin simulations are another example of AI simplifying the job of the machine operator, per the AI report. The virtual environment allows AI to create and test many different iterations of items, like a specific component of a machine, greatly reducing development time and streamlining the development process.

Case Study: Enterprise CP adopts AI-enabled ERP system to accommodate growth

As CPGs navigate growth and continuously carry out complex production operations, leveraging connected workforce technologies can become essential. Enterprise CP (ECP), a Minnesota-based contract packager, learned this when it experienced significant growth over about a four-year span, according to a 2024 Packaging World report. The company implemented a tailor-made, AI-enabled enterprise resource planning (ERP) system to organize its operation as it scaled. Its confident scaling after ERP implementation illustrates how digital technologies can help workers to streamline workflows, reduce errors, and enable faster decision-making in a growing operation.

ECP packages such products as dry mac and cheese, deluxe mac and cheese with liquid cheese pouches, pouch dinners, boxed dinners, and packaged stuffing. It’s retailer customers include Walmart, Kroger, Aldi, and food banks like Feeding America. As the company’s operation quickly grew, it struggled with managing its inventory using outdated systems.

“I was managing eight to 10 spreadsheets to try and keep track of everything,” explains Sandi Hanson, Materials Manager at ECP. “As we continued to grow at such a rapid rate, it became very difficult to manage the upkeep of those spreadsheets.”

Replacing cluttered spreadsheets with digitalization

The need for a more efficient system became apparent as the company expanded. ECP in 2021 turned to Power Central’s ERP software, powered by Microsoft Dynamics 365 Business Central, to address these challenges. The system includes mobile apps purpose-built for the food packaging industry, using Power Apps, advanced Microsoft Cloud, and AI solutions, allowing Power Central to tailor the experience to ECP’s needs.

“Prior to installing the Power Apps, there was mostly a manual system of ensuring FIFO usage of raw materials and shipping of finished goods,” says Hanson. “The Power Apps certainly have made a time savings difference when looking for information and accuracy in fulfillment.”The Power Apps toolkit allows Enterprise CP to digitalize inventory tracking and improve accuracy across operations.Enterprise CP

From the shop floor operator’s perspective, this new technology means a digitalized method of inventory tracking, taking the potential for human error out of the process. Operators can use scanners to quickly and confidently upload inventory information into the system.

This operations-spanning tool has helped to improve collaboration across departments, as Hanson explains, “The ability for the shipping department to see inventory levels and communicate any needs has allowed for adjustments to be made in packaging schedules and for proper fulfillment of finished goods needed to ship.”

AI-powered planning

The system helps ECP’s team forecast future demand and plan accordingly as well, with Power Central’s AI-powered Advanced Planning System. The software uses graph-based algorithms and the inventory tracking from the ERP system to give a visual representation of things like upcoming sales, purchases, and forecasts.

The software uses color coding to highlight purchase orders, with green meaning no inventory issues are ahead. “If I have something that’s orange or turning red, then I know there’s something I need to take a look at. On the purchasing side, I could see if I missed a confirmation, or if I have confirmation that [packaging materials or ingredients] are coming in on that date,” Hanson says. “It’s simple, but it’s a great visual.”

Planning for busy periods or extra requests from customers is also simplified with the Advanced Planning System. A customer can provide its forecast for a timeframe like Thanksgiving, and the system “shows me what raw materials I need to purchase, and if I put it in by month, it’ll show me that I need ‘X’ amount in whatever month it is,” Hanson says. “I can be pretty strategic with when I’m placing my orders and when I’m bringing my inventory in.”

Workers adapt to new technology, as technology also adapts to them

To introduce its workforce to the new ERP system, ECP held training sessions first with process owners, then with material handlers, Hanson says. The company took its time to identify any snags or areas that needed modification, conducting weeks of training and testing before going live with the new system.

Operators shared feedback during the implementation process, which Power Central was able to accommodate. The company made “personalization adjustments” to the system to help it better fit ECP’s specific business needs and user preferences.

The intuitive interface, real-time data access, and AI-based forecasting provided by the system have empowered employees at all levels to make informed decisions quickly. By reducing the reliance on manual processes and spreadsheets, the system has freed up valuable time for employees, contributing to the company’s growth trajectory.

Empowering the workforce through connected tools

The evolution of the connected workforce represents a transformative shift in the packaging industry, offering solutions that enhance operational efficiency and worker engagement.

As CPGs adopt connected technologies, they are not only streamlining production processes but also empowering their workforce. This connectivity facilitates better communication, training, and collaboration across teams and across the production line.