Jerry Dolinsky is the CEO of Dozuki, a leading connected worker solution for enterprise-level manufacturing companies.
Despite significant growth in the manufacturing sector, the pace of knowledge capture lags in our industry.
It creates a critical gap that threatens long-term success.
Consider these two data points:
27% of manufacturing workers are retiring this decade (The Aging of the Manufacturing Workforce, Manufacturing Institute).
97% of manufacturing companies are concerned about the loss of institutional and technical knowledge (The Aging of the Manufacturing Workforce, Manufacturing Institute).
How can manufacturers protect against the loss of valuable institutional knowledge?
I’ve seen firsthand the challenges and opportunities in capturing decades of accumulated process knowledge within manufacturing facilities. Traditional methods are cumbersome, relying on outdated systems that are difficult to navigate or notes scratched in margins in paper binders.
But there is a practical approach to capturing knowledge at scale, without pulling your experts away from critical production tasks. Below I will outline a playbook to help manufacturing companies take a faster path to digitizing and distributing knowledge.
Intelligently Convert Video Into Comprehensive Process Documentation
Standards might live inside people’s heads or on paper, but they’re not documented or agreed upon.
In manufacturing, this can be both dangerous and expensive. When vital knowledge only resides in the heads of experts or in paper binders, you’re already behind. It’s stunning that 95% of manufacturing companies still rely on paper-based processes.
One effective strategy for capturing knowledge at scale is leaning into the generational differences at play. Younger workers (digital natives) are usually more tech-savvy and can help record the processes their older counterparts are teaching them. Not only are they formalizing the knowledge by recording, but they are also learning by osmosis—all while digitizing critical production processes.
To effectively digitize manufacturing processes, follow these instructions:
1. Identify the areas and equipment that require documentation, including various operations, maintenance, cleaning, safety and changeovers.
2. Outline high-level steps for each discrete process to ensure alignment between the videographer and the subject matter expert on what will be demonstrated and recorded.
3. As the subject matter expert demonstrates each step, they should verbalize and provide additional detail and context, ensuring the camera is held steady and directed at the relevant area.
4. If the subject matter expert is not a native English speaker, they may use their native language to ensure accurate narration. For additional context, a dialogue can be held between the subject matter expert and the videographer.
5. Record both before and after the action to capture the full scope of the process being performed.
With the help of artificial intelligence tools, these videos can be instantly converted into standardized, step-by-step guides. This method not only preserves the details of each process but also standardizes the knowledge in a digestible format.
This strategy helps offset the limited number of internal resources available by digitizing processes in days, not months. Now there are few barriers to process documentation.
Harnessing The Power Of Diverse Workforces
27% of manufacturing workers are retiring in this decade, according to The Manufacturing Institute’s report on The Aging Workforce.
In many manufacturing settings, there’s a clear division in skill sets. Older workers often excel at performing processes but may struggle to translate their know-how into written formats. Newer workers are adept at using digital tools but lack the intricate knowledge needed for precise execution.
Does your facility have both? That’s a positive thing for achieving knowledge capture at scale.
To leverage both skill sets for effective knowledge capture, here’s the process I’ve seen many of our customers use. Adapt to your organization’s needs accordingly:
1. Pair experienced workers with tech-savvy colleagues.
2. Have experienced workers demonstrate the processes.
3. Let newer employees record and digitize these processes using digital tools.
4. Replicate that process across facilities, teams and regions to scale up.
This collaboration ensures that the expertise of seasoned workers is accurately documented and easily accessible for training, thus preserving valuable knowledge and empowering the future workforce.
Let Technology Do The Heavy Lifting
Despite the 95% of manufacturing companies still using paper-based processes, we now live in a world where “writing” can be as simple as talking to a coworker. No longer do traditional, labor-intensive, analog methods apply. No longer do we need to rely on outdated systems that are difficult to navigate.
There is a practical approach to capturing knowledge at scale, that doesn’t pull your experts away from critical production tasks. With the right technology, the right collaboration and the right mindset, you can preserve essential skills within your company—all while paving the way for a more dynamic, knowledgeable workforce.
Just make sure you do it before all your experts are gone!
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