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Automation Today 81 | Management Perspectives

Three-pronged Approach to Elevating Your Workforce

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Adrian Giecco filming for ROKStudios.
Issue 81
  • Feature Story
  • Management Perspectives
      • Artificial Intelligence
      • Smart Manufacturing
    • Artificial Intelligence
    • Smart Manufacturing
      • Rockwell Automation
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    • Rockwell Automation
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Adrian Giecco, our regional director of software & control, discusses how manufacturers can use technology to advance workforce skills and attract the next generation of talent.

1. When you talk about workforce empowerment, what does it encompass?

There’s this quote I like which says: “The factory of the future will have only two employees, a man and a dog. The man will be there to feed the dog. The dog will be there to keep the man from touching the equipment”.

The implication is that in the future, it will be lights-out manufacturing with no employees. But the reality has been far from that. Much of what we do in automation is to make it easier, safer and more efficient for industrial workers to do their work. Of course, there’s an amplifying effect of technology in throughput per worker - that’s always been a driver - to reduce cost per unit produced. But it’s more than that. And it’s not just about running the plant, it spans all the activities across the lifecycle of industrial production – design, build, operate & maintain production systems.

It's also increasingly about being able to quickly - and consistently - onboard a new generation of workers, while making their work meaningful and rewarding so they choose to stay. This requires transforming the way work is done with a combination of traditional domain expertise and new technologies.

2. How does Rockwell plan to empower the workforce of the future – both its own and its customers’ – in manufacturing?

There are three areas I’d like to highlight:

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1. Recruit + Train
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First, recruit for the workers you need while growing the skills of the workers you have. This involves attracting workers who are adaptable and tech-savvy, while also reskilling current employees to keep up with rapidly evolving technologies such as AI and cobots. By reshaping roles and focusing on continuous learning, companies can bridge the skills gap and retain a competitive edge.

2. Modernize + Invest
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Second, enable workers to perform higher-value tasks by integrating advanced technologies like automation, robotics, and AI. This shift allows employees to focus on strategic decision-making and problem-solving rather than manual or repetitive tasks. Technology adoption not only enhances productivity but improves job satisfaction and overall impact on business outcomes. Technology and modern digital workflows are essential to attract young talent into manufacturing and industrial production.

3. Futureproof
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Lastly, the rapid influx of technology advancements has led to "technology paralysis," where organizations feel overwhelmed, and unsure which technologies to use. To combat this, firstly create a strategic roadmap for gradual technology adoption based on concrete long-term organizational goals. Pilot projects and partnerships with technology providers are ways to implement digital transformation while minimizing risks. This approach allows businesses to stay competitive and agile in an ever-changing industrial landscape.

Empower People
Woman with orange helmet holding tablet and checking the machine.
Results Achieved
Empower People

Imagine what's possible when everyone is given the tools to succeed.Imagine what's possible when everyone is given the tools to succeed.

3. What role do next-gen technologies like GenAI and digital twin play in boosting workforce productivity and efficiency?

A big role! Let’s discuss some examples.

 

Generative AI

GenAI is a hot technology right now – identified as the #1 area for investment in 2024 in our recent State of Smart Manufacturing Report , and the #2 area for ROI, only second to cloud. It’s important to note that GenAI isn’t yet reliable enough when it comes to the physical world, so you wouldn’t put it in the control loop without human oversight. But GenAI can be amazing in the way of industrial copilots, assisting and guiding humans to deal with the “museum” of equipment and technologies present in many industrial settings.

Some of the copilots that are emerging to empower workers are:

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1. Design Copilots
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Copilots such as the one newly embedded in FactoryTalk® Design Studio™ will increasingly help users answer how-to questions, and explain and generate PLC/DCS code based on natural language prompts. This is a great way of leveraging the new skills of today’s graduates, while bridging the gap in traditional automation programming languages.

We will also soon see copilots or agents which automatically generate new PLC and HMI artifacts from “upstream” design deliverables such as CAD drawings and system functional requirements.

The bottom-line is improved speed and simplicity of the end-to-end production system design lifecycle.

2. Operation Copilots
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These copilots provide on-demand production insights by “chatting” with live and historical production and engineering data. We’re starting to embed copilot functionality into our DataOps platform FactoryTalk® DataMosaix™ and we will also likely see them embedded directly into HMI platforms.

3. Maintenance Copilots
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These context-aware copilots help with alarm analysis and troubleshooting. This is made possible through a combination of large language models (LLMs) to interpret the context of alarms, and a technique called retrieval-augmented generation (RAG) which allows the LLMs to access external up-to-date knowledge bases, such as manufacturer documentation.

This approach allows maintenance copilots to offer more accurate, context-specific assistance, effectively empowering workers to handle complex maintenance tasks more efficiently with step-by-step guidance.

Digital Twins Simulated models of the production system provide a safer and versatile training ground for workers. It’s like a flight simulator, where instructors can pre-load and recreate unique scenarios for personnel to learn challenging scenarios without disrupting production.

An example of this is our collaboration with NVIDIA where we integrated their omniverse cloud

application programming interfaces (APIs) with Emulate3D™, bringing users data interoperability, live collaboration, and physics based visualization for designing, building, and operating industrial-scale digital twins of production systems.
 

4. You mentioned Artificial Intelligence – how does AI augment and not replace workforce?

For the last 200 or so years, every major industrial technology breakthrough has triggered a similar question – will this innovation replace workers? Will it drive unemployment? But time and time again, the impact has been largely positive.

New industrial technologies drive productivity and cost reduction, driving increased demand and new market creation - generating new jobs.
Emulate3D software cuts install and commission time by up to 50%
Emulate3D software cuts install and commission time by up to 50%
Case Study
Case Study
Emulate3D software cuts install and commission time by up to 50%
ECM Technologies’ uses Emulate3D™ software to remove installation and commissioning challenges in the development, testing and deployment of large-scale heat treatment plants.

While we cannot deny that some jobs will be drastically transformed or even lost, there’s a strong track record of net job creation.

We discussed how design copilots will be able to take natural language descriptions of a manufacturing process and generate control code. This means that control engineers may soon be two to five times more productive with these tools. That compresses development time and frees them up for higher value activities.

An example is the use of AI to simplify and scale proven techniques. Take predictive maintenance – this has been around for decades, but it hasn’t been broadly implemented in many industries due to lack of domain expertise and complexity to configure and maintain. With semi-supervised learning, maintenance teams can quickly implement anomaly detection and MTTF prediction for manufacturing assets, scaling rapidly across all assets.

For instance, we worked with a major metals and mining brand to inject AI-based anomaly detection using FactoryTalk® Analytics™ GuardianAI™ to increase their profitability and prevent full-shift downtime.

In this sense, AI will democratize productivity practices that were too costly or resource-constrained to implement at scale.

Another example is the use of machine learning (ML) to improve the performance of controls for complex or highly variable processes that are difficult to model. Here, control engineers use supervised and reinforcement learning as tools to improve the output of their work. These ML-based models often outperform the traditional “set & forget” expert-based models, delivering increased Overall Equipment Effectiveness (OEE) and continuously adapting to the changing environment. 

 Adrian Giecco
Adrian Giecco
Software & Control Director, Asia Pacific, Rockwell Automation
Adrian leads a team of more than 100 engineers and consultants spanning 14 countries. Together they bring to market a suite of technologies that help manufacturers transform their operations. Adrian has more than 15 years’ experience in industrial control & information technology. Throughout his career, Adrian has managed complex automation projects, large engineering teams and innovative technology portfolios across multiple countries. He also co-founded an IoT start-up to help farmers be more sustainable.
Connect:
Topics: Digital Transformation Industrial Analytics Software Evolution FactoryTalk Design Studio FactoryTalk DataMosaix FactoryTalk Analytics GuardianAI Emulate3D Digital Twin
AI in Manufacturing
ai-manufacturing
ROKStudios
AI in Manufacturing

Artificial intelligence (AI) in manufacturing isn’t new. GenAI is. Our software & control director Adrian Giecco discusses the impact it will bring to shop floors.

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