Why the future of manufacturing software is horizontal

If you’re a manufacturer in 2023, then you likely have an abundance of digital systems. But do you view your digital transformation project to date as a success for workers on the line?

If the answer is yes, congratulations. For most this is far from true. A patchwork of disparate solutions, custom built sticking plasters that are expensive to maintain and paper/whiteboards or spreadsheets likely make up the experience for your frontline workforce.

This means critical data is missing from decision making in the black hole of frontline operations. So why is that?

Software solutions in manufacturing have evolved over time, targeting specific problem verticals rather than taking a broad, horizontal approach. It all began with early computerized systems in the 1960s and 1970s, which automated basic tasks like inventory management and production scheduling. Over time, solutions have been developed around specific process gaps. ERP, CMS, QMS and EHS systems to acronym drop a few were brought in focused on verticalized solutions for specific business problems.

This model works well for knowledge workers, who typically buy the solutions. If you’re an EHS director then you need a verticalized EHS solution just like an accountant needs accountancy software. But operational workers have completely different needs to knowledge only workers. They are the entry point to so many different work processes on a daily basis that for them to go fully digital in a vertical way would require them to interact with dozens of apps each shift.

Equally, it would require vertical solutions to build capabilities that cover a wide range of use-cases unique to industrial operation. Not surprisingly, they aren’t there yet. The diagram below maps out the different work process that exist in a typical process manufacturer mapped across Safety, Quality, Cost, Delivery, People and Environment (SQCDPE). What we tend to see for manufacturers who have rolled-out the major core systems is that although some of the work processes on the shop floor have been digitalised in vertical solutions, the majority have not and are found on pen/paper & whiteboards.

This means as a frontline worker in an advanced manufacturer my work is split across different systems, paper and excel. On top of this, many use-cases that ought to live in these systems in practice don't due to the complexity of training this out.

So what does this mean?

Well, this is a problem. This means that for supply chain leader, the majority of data needed to get an accurate view of how their plants are doing across SQCDPE is missing. For operators, they are left trying to run a factory with a jumbled mash of Paper, Spreadsheets and ill-fitting verticalized software.

To meet this challenge we are seeing many of the enterprise systems developing a ‘mobile’ front-end for their solutions. I don’t know who needs to hear this, but THIS IS NOT THE ANSWER!

How many production lines have you seen that don’t already have easy access to a desktop computer with access to these solutions? Are they driving meaningful value for your workers today? Adding a mobile interface is only an incrementally better way to access the systems but it falls far short of rising to meet the business challenge of a dwindling and under-developed workforce.

So now what?

What if we flipped the model and went back to the drawing board to build something with the end-user in mind. An end-to-end integrated solution that will seamlessly guide me from the start to the end of my shift? It’s happening in other industries: Figma completely displaced the design stack by providing an end-to-end solution for designers, Foundry changed the film industry forever by supporting animators from start to finish and MS teams seemed to replace video conferencing, instant messaging and corporate communication overnight by providing an integrated solution for team communication.

So what would this look like in manufacturing? Well firstly, let’s acknowledge that every organization works, makes and tracks differently. Any solution needs to respect that and provide flexibility to adapt to your organization. This is why an end-to-end solution for frontline operations needs to provide highly configurability capability across task, knowledge and skill management. It also needs out of the box integrations to connect the systems of record to ensure information flows. If this is done right, then workers can be guided through their shift across SQCDPE activity.

The Future of The Manufacturing Technology Ecosystem

If we re-designed the OT stack with the goal of helping the frontline workforce then we would arrive at a different solution. Imagine if I was guided from the start of shift to the end of shift across all shop floor activity. At every stage i'm backed up with work instruction, data, AI insight and expert support. Imagine if I was building my own skills card as I did that and given the opportunity to learn on the job.

The core systems of record are freed from needing to cater for the frontline worker and can focus on being world-leading in their verticals. There is a lot of cool stuff happening in the EHS and QMS space for example which i'd love to see continue.

The diagram below shows how a single-interface can guide workers from the start of shift to the end of shift across SQCDPE activity. At every stage data is sent to and from the enterprise IT stack through a standard set of core integrations.

This gives supply chain leaders a 360 degree view of plant activity, the insight to identify key improvements and a mechanism to enact meaningful change. This will result in a better equipped workforce, armed with the context and knowledge they need to drive real change on the factory floor. We’ve seen this drive OEE, Quality, Safety and more in a big way.

So, what about MES?

MES (Manufacturing Execution Systems) have been heralded as the poster child of ‘going paperless on the shop floor’ for some time. But seldom has it lived up to this hype. MES has an important role to play now and in the future, but it’s not the only answer. MES, AKA Means Everything Somewhere – takes a different meaning to different people. This is because MES is a collection of capabilities that don’t necessarily need to be connected.

Here is a list of capabilities you may (or may not!) find in an MES:

1. Digital recipe management
2. Traceability & Quality
3. Production Planning
4. Inventory management
5. Performance management
6. Data analysis
7. Workflow management
8. Historian / PI

For each of these items you will find best in class next generation solutions taking advantage of AI, BlockChain, AR/VR and other technologies which the traditional MES players mostly haven’t yet. The cost of procuring and integrating software is lower than ever with standards like ISA-95 and OPC UA simplifying connectivity. Why not procure the best in class solution for each based on the highest priority business need?

So what would this look like for workers? At Zaptic we see the future for connected worker as horizontal. Connected worker platforms should guide workers from the start of shift to the end of shift, across all SQCDPE activity. Core systems such as ERP, QMS and even MES are deployed to act as vital specialised capability. It’s the job of the connected worker platform to do just that, connect workers to these systems.

By doing so we want to guide workers from start to end of shift by giving them the information and guidance to know the what, where and how of daily execution. All the while building capability in the workforce to bridge the skills gap. Waze has lowered the barrier of entry to drive taxis, squarespace makes anyone a web designer and a truly horizontal connected worker platform has the power to solve a global skills crisis.