Industrial AI doesn’t have a data problem—it has a context problem. Learn why execution intelligence is the missing link between AI insights and real manufacturing outcomes.

Nearly every industrial technology conversation today revolves around AI. Manufacturers are evaluating copilots, autonomous agents, industrial knowledge graphs, digital workers, and generative AI. Software vendors are racing to demonstrate how AI can automate decisions, improve productivity, and streamline operations.

Yet amid all of the excitement, one critical question often goes unanswered: What data is this AI actually using to using to make decisions?

For many industrial AI initiatives, the answer is familiar—machine telemetry, ERP transactions, MES records, CMMS work orders, quality systems, and historian data. These systems provide valuable operational information, but they only tell part of the story. Manufacturing performance depends not only on machines and processes, but also on how people execute work.

Every maintenance task, inspection, changeover, startup, quality check, and standard operating procedure depends on frontline workers making thousands of decisions every day. Those decisions generate an enormous amount of execution data, yet that information has historically been difficult to capture, structure, and analyze at scale.

system of context the missing layer

Without understanding how work is actually performed, AI has an incomplete view of operations. It may have data, but it lacks context—and in manufacturing, context is what transforms AI from simply generating answers into driving the right actions.

Context is What Separates AI from Action

Today’s large language models (LLMs) are remarkably capable. They can summarize documents, generate procedures, answer questions, and analyze massive amounts of information. But LLMs don’t inherently understand manufacturing operations. They rely on rich operational context to reason effectively, enabling AI agents to make informed decisions and take meaningful action. Without that context, even the most advanced models are limited.

An AI agent may receive a signal from an IoT sensor indicating abnormal equipment vibration, recognize declining production output from MES data, or identify an increase in quality defects from a QMS. What it often cannot determine is whether the technician assigned to the work has the right skills, certifications, proficiency level, and experience to perform the repair, whether they’ve successfully completed similar work in the past, whether the operator has recently completed training, if standard work is actually being followed, or what tribal knowledge experienced workers have developed that never made it into the SOP.

Without this context, AI can generate recommendations. With it, AI can make informed decisions, personalize guidance, orchestrate work, and drive execution.

system of context drives ai action

As AI moves beyond answering questions to initiating actions, governance becomes just as important as context. Manufacturers need confidence that AI agents operate within defined permissions, business rules, security policies, and human approval workflows. Context enables AI to make better decisions; governance ensures those decisions are safe, transparent, auditable, and aligned with operational and regulatory requirements.

Building a System of Context

Manufacturers have spent decades investing in systems that collect operational data. ERP platforms manage business transactions, MES platforms manage production, CMMS platforms manage maintenance, QMS platforms manage quality, and historians collect equipment and process information.

That investment is only accelerating. Deloitte’s 2025 Smart Manufacturing and Operations Survey found that 92% of manufacturers believe smart manufacturing will be the primary driver of competitiveness over the next three years. As manufacturers continue investing in AI and connected technologies, they’re generating more operational data than ever before—but more data alone doesn’t create better AI. It must be transformed into context.

A system of context isn’t built by integrating enterprise systems alone. It is built by continuously capturing how work is actually performed across the factory.

ERP systems manage business transactions. MES tracks production. CMMS manages maintenance. QMS captures quality events. Historians and IoT platforms monitor equipment performance. Together, these systems describe what is happening across the operation.

The missing layer is how work gets done.

This is where AI-native connected worker platforms fundamentally change the equation. Unlike traditional software that simply digitizes work, an AI-native platform continuously captures the execution of work itself—how tasks are performed, who performs them, how long they take, where workers encounter friction, when assistance is required, which procedures produce the best outcomes, and how worker skills, proficiency, and experience influence operational performance.

system of context equation

Every completed procedure, inspection, maintenance activity, changeover, quality check, and guided workflow becomes another source of execution intelligence.

Unlike static operational data that simply records what happened at a point in time, execution intelligence compounds with every task performed. Each new execution expands the platform’s understanding of workforce performance, creating an ever-growing foundation of operational knowledge.

Execution intelligence is the continuous measurement and AI-driven understanding of frontline work—capturing not only what workers do, but how effectively they perform, what drives performance variation, and where opportunities for improvement exist.

As millions of frontline work activities are captured, AI continuously structures, cleans, and normalizes the data, distinguishing normal variation from true performance opportunities. Over time, it builds an increasingly rich understanding of how work is performed, how well it is performed, and the factors that consistently drive better operational outcomes.

This is what creates a true system of context. Enterprise systems provide the operational state of the factory. Connected worker platforms provide the execution history of the workforce. Together, they create the relationships AI needs to understand not only what happened, but who performed the work, how it was executed, what influenced the outcome, and what should happen next.

Technologies such as industrial knowledge graphs play an important role by organizing these relationships, but the graph is only as valuable as the context it contains. The real advantage comes from continuously generating new execution intelligence—not simply connecting existing records.

This is where AI-native platforms establish a durable data advantage. Every workflow completed, every task executed, and every AI-optimized time & motion study expands the platform’s understanding of how work is performed. After analyzing millions of real-world execution events, AI begins to understand not only what happened, but why it happened, which workers consistently achieve the best outcomes, what behaviors lead to success, and how those best practices can be replicated across the workforce.

Over time, this creates a proprietary foundation of workforce intelligence that becomes increasingly difficult to replicate. Rather than relying on static historical records, AI continuously learns from the daily execution of work itself—enabling AI agents to make better decisions, personalize guidance for every worker, orchestrate work across enterprise systems, and drive continuous operational improvement.

Closing the Context Gap

Industrial AI is advancing rapidly, but its long-term value won’t be determined by the size of the language model or the sophistication of the AI agent. It will be determined by the quality of the context those systems can reason over.

Manufacturers have spent decades digitizing machines, equipment, and enterprise processes. The next frontier is digitizing the execution of work itself—capturing not only what happens on the factory floor, but how work is performed, how performance varies, and why some workers, teams, and processes consistently achieve better outcomes than others.

This is where Augmentir takes a fundamentally different approach. From the beginning, the platform was designed as an AI-native connected worker platform—not simply to digitize frontline work, but to continuously learn from it. Every guided workflow, every completed procedure, every captured skill, and every AI-optimized time & motion study contributes to a growing foundation of execution intelligence that helps AI better understand the realities of manufacturing operations.

That continuously expanding understanding closes the context gap between enterprise data and frontline execution. It enables AI to move beyond answering questions or generating recommendations to delivering personalized guidance, orchestrating work, identifying improvement opportunities, and driving measurable operational outcomes.

As industrial AI continues to evolve, manufacturers won’t compete based solely on who has the most AI. They’ll compete based on who has the richest understanding of how work gets done. Because in manufacturing, context isn’t just another input to AI—it is the foundation that turns intelligence into action. Combined with strong governance, security, and human oversight, it also ensures that those actions are trustworthy, auditable, and aligned with the operational and safety requirements of modern manufacturing.

 

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Frequently Asked Questions (FAQ)

  • What is execution-driven industrial AI in manufacturing?

    Execution-driven industrial AI combines artificial intelligence with workforce intelligence and operational data to help manufacturers make better decisions and automate work on the factory floor. Instead of simply analyzing machine data, execution-driven AI understands how work is performed, who is performing it, and what actions should happen next. Augmentir's AI-native Connected Worker platform enables execution-driven industrial AI by connecting workers, work, and enterprise systems to continuously improve safety, quality, productivity, and operational performance.

  • Why do AI agents in manufacturing need workforce intelligence?

    AI agents in manufacturing need workforce intelligence because machine and operational data alone do not provide enough context to make informed decisions. Workforce intelligence includes worker skills, certifications, proficiency, training history, and step-level execution data. Augmentir captures and analyzes this information to give AI agents the context they need to recommend actions, orchestrate workflows, personalize worker guidance, and continuously optimize manufacturing operations.

  • How does Augmentir use AI agents to improve manufacturing operations?

    Augmentir uses AI agents to help manufacturers automate and optimize frontline operations. Built on an AI-native Connected Worker platform, Augmentir's AI agents leverage workforce intelligence, digital work instructions, and data from ERP, MES, CMMS, QMS, and historian systems to assist workers, coordinate multi-step workflows, support maintenance and quality processes, and drive continuous improvement across the factory.

In the latest Manufacturing Talks episode, Chris Kuntz joins Jim Vinoski to discuss Augmentir and how the world’s most innovative manufacturers are using Augie, an Industrial Gen AI solution, to revolutionize frontline operations. From real-time insights to enhanced efficiency, Augie is reshaping the shop floor.

The manufacturing industry is embracing AI like never before!

In the latest Manufacturing Talks episode, Chris Kuntz joins Jim Vinoski to discuss Augmentir and how the world’s most innovative manufacturers are using Augie, an Industrial Gen AI solution, to revolutionize frontline operations. From real-time insights to enhanced efficiency, Augie is reshaping the shop floor.

 

 

See how Augmentir’s TWI software supercharges Training Within Industry’s four pillars with AI-driven personalization, safety, and continuous improvement.

For more than 80 years, Training Within Industry (TWI) has been a proven foundation for building skilled, capable workforces. Organizations in manufacturing, food and beverage, and other industrial sectors have relied on its structured approach to Job Instruction (JI), Job Methods (JM), Job Relations (JR), and Job Safety (JS) to ensure quality, productivity, and employee engagement.

supercharging training within industry with twi software from augmentir

At Augmentir, we’re not here to reinvent TWI. We’re here to amplify it—to give it the tools it needs to thrive in the modern, connected, data-driven world.

Recently, a food and beverage company that has followed TWI principles for over 20 years shared with us how Augmentir’s Connected Worker software is helping them unlock value they didn’t realize they were losing.

Our TWI software builds on TWI’s four pillars by combining their time-tested structure with modern digital capabilities—AI-driven personalization, real-time data capture, integrated safety workflows, and collaborative improvement tools—that close long-standing gaps, preserve the integrity of the methodology, and extend its impact across today’s fast-changing industrial landscape.

Pillar 1: Job Instruction – From Good to Great

One of our client’s first observations was that Job Instruction isn’t as simple as writing a standard operating procedure. Get the structure wrong, and the benefits of TWI start to slip away.

Their feedback? Our ability to configure job instructions exactly to their needs is helping them reclaim value that had been leaking from their process for years. Instead of rigid templates, Augmentir’s TWI software allows Job Instructions to be built and delivered in ways that match the precise structure, flow, and visual cues required for mastery.

Even better, our AI continuously assesses each worker’s knowledge and adapts the training to meet them where they are—so no one sits through irrelevant steps and no one is left behind.

Beyond personalization, our AI agents act as always-on digital trainers. Workers can ask questions in natural language at the moment of need, get step-by-step coaching during unfamiliar tasks, and receive proactive nudges when an agent detects hesitation, errors, or a deviation from the standard. The result is true on-the-job training—where Job Instruction is reinforced every shift, not just during onboarding.

Pillar 2: Job Methods – Continuous Improvement, Powered by the Frontline

In classic TWI, Job Methods is about refining the way work gets done. Our client has seen this pillar transformed with Augmentir.

By enabling workers to contribute improvement ideas at any step of work, they have seen a 20% increase in job improvement recommendations over last year. These aren’t just suggestions—they’re captured, evaluated, and acted on with a closed feedback loop, creating a living system of operational improvement.

Our AI detects variability in work execution and pinpoints where skills gaps exist, driving targeted upskilling opportunities that improve both productivity and consistency.

Pillar 3: Job Relations – Objective Insights that Build Stronger Teams

For TWI, Job Relations is about fostering trust, communication, and engagement. Augmentir’s AI agents continuously monitor skill progression, certification status, and on-the-job performance—giving leaders a real-time view of how each operator is developing, where they’re excelling, and where they need support.

This isn’t about surveillance—it’s about partnership. Supervisors can have objective, meaningful conversations with workers, backed by clear metrics and personalized development paths. Our client reported that this is improving retention, engagement, and happiness scores—and ultimately strengthening the relationship between employees, leaders, and the organization as a whole.

Pillar 4: Job Safety – The Modern Essential

While traditional TWI implies safety as a byproduct of strong training, modern operations demand more. Our client pointed out something powerful:

“Having an employee trained makes them safer. But Augmentir’s ability to tailor training to the specific knowledge of each person makes them even safer.”

With Augmentir, safety becomes a core, trackable element of daily work:

  • Safety prompts embedded directly into digital workflows.
  • Real-time hazard alerts and compliance checks.
  • Data-driven insights to proactively address risks before incidents occur.

By elevating Job Safety to a pillar of its own, organizations can make safety culture measurable, visible, and consistently reinforced.

Extending TWI Software with Custom AI Agents

Every TWI program is unique. The way one organization captures skill progression, validates certifications, or coaches new hires looks very different from the next. That’s why Augmentir’s TWI software and AI Agent Studio gives manufacturers the tools to build their own AI agents—purpose-built for their specific TWI workflows, terminology, and operating standards.

industrial ai agent studio - build custom ai agents for manufacturing

With AI Agent Studio, teams can deploy custom agents that:

  • Track operator skill progression against TWI-defined competencies and surface gaps before they affect quality or safety.
  • Coach new hires through Job Instruction breakdowns, adapting guidance to the worker’s experience level and learning pace.
  • Recertify operators on critical tasks by quizzing them in context, scheduling refreshers, and flagging expirations to supervisors.

Rather than waiting for a vendor roadmap, manufacturers can stand up agents in minutes—turning their hardest-won TWI knowledge into a system that scales across lines, plants, and shifts.

The Future of TWI Software is Connected

TWI’s principles have stood the test of time since their introduction during World War II because they work. But today’s operations are more complex, the pace of change is faster, and the demand for agility is higher than ever.

By combining TWI’s enduring framework with Augmentir’s AI-powered Connected Worker platform, companies can:

  • Deliver Job Instructions that truly fit the work and the worker.
  • Make Job Safety a measurable, proactive outcome.
  • Harness frontline input for continuous improvement at scale.
  • Use objective insights to strengthen relationships and grow talent.

This isn’t about replacing TWI—it’s about giving it the digital muscle to thrive for the next 80 years.

Ready to take TWI further? See how Augmentir’s Connected Worker platform and AI Agent Studio can amplify every pillar of your training program. Book a Demo.

 

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Augmentir welcomes Mike Carroll to our Board of Advisors! Mike is widely recognized as an industry trailblazer and visionary, with a proven track record of driving innovation, industrial transformation, and AI strategy.

We’re excited to welcome Mike Carroll to Augmentir’s Board of Advisors!

A recognized leader in industrial operations, digital innovation, and workforce strategy, Mike brings decades of experience driving transformation across manufacturing and industrial enterprises.

augmentir welcomes mike carroll to board of advisors

Widely regarded as an industry visionary, Mike most recently served as Vice President of Innovation at Georgia-Pacific, where he led transformative initiatives across the company and its parent, Koch Industries. His leadership in AI strategy, operational excellence, and workforce enablement makes him a powerful addition to Augmentir as we continue to grow our AI-powered connected worker platform — helping manufacturers tackle their most critical workforce challenges.

A Career at the Intersection of Manufacturing, Innovation, and Industrial Transformation

Mike’s career spans key leadership roles where he has helped organizations modernize operations by aligning people, process, and technology. At Georgia-Pacific, he led enterprise-wide efforts in operations, engineering, and manufacturing excellence, creating more adaptive, future-ready workforces.

His expertise extends beyond technology adoption — encompassing workplace modernization and the human side of digital transformation. These experiences make him a valuable voice in the evolving conversation about the future of work.

Why This Matters Now

Manufacturing is undergoing a seismic shift. With aging workforces, widening skills gaps, labor shortages, and increasing production complexity, manufacturers are being forced to rethink how they engage, support, and train their frontline teams.

At the same time, emerging technologies like AI, connected worker platforms, and intelligent automation are opening new opportunities — but only when implemented with real-world operational understanding.

That’s where Mike’s experience is invaluable. Having led transformation initiatives from within the industry, he brings both a strategic lens and practical wisdom to ensure that workforce transformation remains central to industrial innovation.

Mike has a unique ability to connect operational goals with frontline execution. His strategic vision and practical insight will be a tremendous asset as we continue helping manufacturers digitize their frontline operations and unlock workforce potential through AI.

We see the future of industrial work now being realized by emerging AI approaches, utilizing generative AI knowledge management, and AI factory agents collaborating alongside humans on the shop floor. Augmentir’s focus on delivering an intelligent frontline operations platform goes beyond visualizing data to actually driving action. It digitally connects people, processes, and systems, enabling proactive management through intelligent workflows, digital task management, and continuous improvement tools. With Augmentir, data isn’t just displayed—it’s used to empower smarter, faster, and more effective operations.

“Augmentir isn’t just another layer of dashboards, it’s goal is to be a unified ‘single pane of glass’ that closes the loop between training and work execution, empowering frontline teams with AI-driven insights and augmented guidance to drive continuous improvement in safety, quality, and productivity. I’m excited to join a company that doesn’t merely digitize processes but learns from every action on the shop floor and delivers in-line support, whether through generative AI assistants or remote expert collaboration, so manufacturers can onboard workers faster, optimize skills, and unlock their full potential.”

– Mike Carroll

Driving the Future of Connected Work

At Augmentir, we’re committed to helping manufacturers digitize and optimize their frontline operations with AI-powered tools for skills management, digital workflows, industrial collaboration, and continuous improvement.

Welcoming Mike Carroll to our Board of Advisors is another step forward in that journey — strengthening our ability to serve manufacturers with both cutting-edge technology and real-world operational insight.

Please join us in welcoming Mike to the team!

 

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How AI, HR, and operations come together to support frontline workers. Key insights from the HR Happy Hour podcast, featuring Chris Kuntz from Augmentir on skills, training, and connected work.

Augmentir’s VP of Marketing, Chris Kuntz, recently joined Steve Boese on the System of Record podcast from the HR Happy Hour Network to talk about a topic that doesn’t get nearly enough attention: how AI, operations, and HR come together to support the frontline workforce.

hr happy hour podcast with chris kuntz from augmentir

Listen Now

While much of the AI-at-work conversation focuses on desk and knowledge workers, Chris and Steve shifted the spotlight to the 65% of the workforce who work on factory floors, in distribution centers, and out in the field—and how technology can be used to augment and empower, not replace, them.

Below are the key themes and insights from the conversation.

The Missing Link in Industrial Transformation: People

Chris shared his background in industrial and emerging technologies, including his work helping pioneer Industrial IoT at ThingWorx. After years of making machines smarter and more connected, his team recognized a critical gap in Industry 4.0 and 5.0 initiatives:

Humans were the missing piece.

Frontline workers—despite being essential to safety, quality, and productivity—have historically been underserved by technology. Post-pandemic workforce shifts have only intensified the challenge, with:

  • Shorter average tenure
  • Less experience on the job
  • Higher early attrition rates

These trends make traditional six-month onboarding models unsustainable and force organizations to rethink how they support and develop frontline talent.

Augmentir’s Focus: Closing the Skills and Experience Gap

Founded in 2018, Augmentir is an AI-native connected worker platform designed to address what Chris calls the most critical problem in manufacturing today: the combination of labor shortages, skills gaps, and experience gaps.

Rather than treating frontline technology as just digitized paperwork, Augmentir connects workers directly to the digital thread of the business, integrating:

  • Operational systems (ERP, MES, QMS)
  • Learning and training platforms
  • HR systems and skills data

This creates a single interface where workers are active participants in the digital ecosystem—while giving leaders unprecedented visibility into performance, skills, and improvement opportunities.

From Paper Procedures to Continuous Improvement

Chris described how many industrial processes have historically relied on paper instructions or tribal knowledge. By digitizing standard work and connecting workers digitally, organizations can:

  • Capture real-time performance data
  • Identify skill gaps and training needs
  • Reduce safety incidents, rework, and downtime

Augmentir applies machine learning to analyze hundreds of data points—from task duration to error rates—to surface insights such as:

  • Where individuals may need targeted training
  • Where processes or content need improvement
  • How onboarding and training programs are performing

For plant managers and operations leaders, this replaces backward-looking reports with actionable, real-time decision support.

Worker Empowerment, Not Surveillance

A key part of the discussion focused on worker trust and experience. Chris emphasized that successful connected worker initiatives are grounded in empowerment, not micromanagement.

When frontline employees are involved early in the rollout and change management process, the technology is seen as a tool that:

  • Helps them do their jobs safely and correctly
  • Reduces frustration and guesswork
  • Recognizes and rewards positive behaviors

From reporting safety issues to improving efficiency, these signals also provide valuable engagement insights for HR—bridging a gap that has long existed between HR and operations.

Bridging HR and Operations

One of the most compelling themes was the disconnect between HR systems and day-to-day operations. Skills matrices, certifications, and training data often live in HR tools that operations leaders can’t easily access.

By bringing skills and competency data directly into operational workflows, organizations can:

  • Schedule work based on real capabilities
  • Identify reskilling and upskilling needs
  • Measure the effectiveness of training programs

For HR leaders, this turns training ROI from a “black box” into something measurable and defensible.

The Rise of AI Agents on the Frontline

Chris also shared how Augmentir evolved beyond analytics into AI assistants and agents. From its generative AI factory assistant Augie to emerging agentic use cases, the vision includes:

  • Digital lean coaches
  • Training and skills agents
  • Root cause analysis (“5 Whys”) agents
  • Quality agents
  • Safety agents

Importantly, Augmentir has established clear guardrails—such as human-in-the-loop approvals and deterministic logic for safety-critical tasks—to ensure AI supports workers responsibly; these principles are codified in Augmentir’s Six Laws of Agents.

What’s Next: A Human-Centered Future of Work

Looking ahead, Chris highlighted how leading manufacturers like Colgate-Palmolive and Hershey are creating new roles that blend HR and operations, focused on people capability and performance excellence.

The most exciting trend?

Companies are using technology to make frontline work better—faster onboarding, skills development in the flow of work, higher retention, and a stronger sense of purpose for workers.

By truly aligning people, process, and technology, these organizations are redefining what frontline work can look like.

Listen to the Full Conversation

To hear the full discussion on connecting HR, operations, and AI for the frontline workforce, check out the System of Record podcast on the HR Happy Hour Network.

Request a demo to learn more about Augmentir or connect with Chris Kuntz on LinkedIn to continue the conversation.

 

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The evolution of AI in manufacturing has seen tremendous growth over the past few decades, now becoming more adaptive and collaborative, and being used to augment and directly support frontline workers.

The evolution of artificial intelligence and machine learning technologies in manufacturing has seen tremendous growth over the past few decades, with astounding leaps in technology and industry-wide transformations.

evolution of ai in manufacturing

Dating back to the 1960’s, manufacturers started using AI in robotics and basic automation. This early usage focused on automating manual, highly repetitive human tasks such as assembly, parts handling, and sorting, allowing for higher levels of production and efficiency.

Over time, this evolved with AI-enabled machine vision systems, which were used to automate visual inspections, allowing for better quality control and precision during production cycles. More recently, AI has been at the center of warehouse automation, as well as the Industrial Internet of Things (IIoT), where physical machines and equipment are embedded with sensors and other technology for the purpose of connecting and exchanging data, which is used in predictive analytics for machine health monitoring. Manufacturers can now glean valuable insights from data collected over time about optimizing their operations for maximum efficiency without sacrificing quality.

Despite the breath of applications that AI has in the industrial setting, there is a common thread across all of the above examples – AI has largely been used to automate highly repetitive or manual tasks, or perform functions designed to replace the human worker.

These examples laid the groundwork for the adoption of AI in manufacturing and for the use of AI technologies that augment and directly support frontline workers today.

Read below for more information on how the use of AI and GenAI is evolving in manufacturing, and being used to augment the human worker, transforming productivity and efficiency at a time when workforce optimization is needed most.

Using AI to Augment, not Replace the Workers in our Factories

Today, AI technologies in manufacturing have evolved to encompass a diverse range of applications. According to Deloitte, 86% of surveyed manufacturing executives believe that AI-based factory solutions will be the primary drivers of competitiveness in the next five years. Robotics and automation have become more adaptive and collaborative, working alongside and augmenting human workers to streamline production processes and increase efficiency – rather than simply trying to replace them.

As computing power and algorithmic capabilities improved, AI in manufacturing has become more advanced and widespread. The emergence of Industry 4.0, characterized by the convergence of digital technologies, further accelerated AI’s role in manufacturing. By leveraging tools like connected worker solutions to gather frontline data, manufacturing organizations can now capitalize on AI’s extraordinary computing power to analyze that data and derive actionable insights, improved processes, and more.

Much like the industry has learned to optimize equipment from the 1.7 Petabytes of connected machine data that is being collected yearly, we are now able to optimize frontline work processes and people from highly granular connected worker data, with one major caveat: In order to leverage this incredibly noisy data, a system has to be designed with an AI-native strategy, where the streaming and processing of this data is intrinsic to the platform – not added as an afterthought.

The potential for AI to help augment the human worker is there, but why now?

Because for today’s manufacturers, time is not on your side.

The workforce crisis in manufacturing is accelerating, and at the forefront of the minds of Operations and HR leaders. Job quitting is up, tenure rates are down, and manufacturers struggle daily to find the skilled staff necessary to meet production and quality goals. The threat is huge – with significant impacts to safety, quality, and productivity.

AI-based connected worker solutions allow industrial companies to digitize and optimize processes that support frontline workers from “hire to retire”. These solutions leverage data from your connected workforce to optimize training investments and proactively support workers on the job, across a range of manufacturing use cases.

 

paperless factory

Furthermore, solutions that leverage Generative AI and proprietary fit-for-purpose, pre-trained Large Language Models (LLMs) can enhance operational efficiency, problem-solving, and decision-making for today’s less experienced frontline industrial workers. Generative AI assistants can leverage enterprise-wide data, provides instant access to relevant information, closes skills gaps with personalized support, offers insights into standard work and skills inventory, and identifies opportunities for continuous improvement.

Augmentir’s AI-Native Journey

At Augmentir, since the beginning, we pioneered an AI-native approach toward manufacturing and connected frontline worker support. 

augmentir ai-native journey

Many manufacturing solutions incorporated AI technology as an add-on or afterthought as the technology gained more advanced capabilities and popularity. We, however, have been championing and building a suite of solutions using AI as a foundation. Our platform was designed from the bottom up with AI capabilities in mind, placing us as a leader in the connected frontline worker field. 

  • 2019 – Augmentir launched the world’s first AI-native connected platform for manufacturing work empowering frontline workers to perform their jobs with higher quality and increased productivity while driving continuous improvement across the organization. This marked the start of our AI-native journey, giving industrial organizations the ability to digitize human-centric work processes into fully augmented procedures, providing interactive guidance, on-demand training, and remote expert support to improve productivity and quality.
  • 2020 – Augmentir unveiled True Opportunity™, the first AI-based workforce metric designed to help improve operational outcomes and frontline worker productivity through our proprietary machine learning algorithms. These algorithms take in frontline worker data, then combine it with other Augmentir and enterprise data to uncover and rank the largest capturable opportunities and then predict the effort required to capture them.
  • 2021 – Building on user feedback and field data, Augmentir reveals True Opportunity 2.0™, with improved and enhanced capabilities surrounding workforce development, quantification of work processes, benchmarking, and proficiency. By Leveraging anonymized data from millions of job executions to significantly improve and expand the platform’s ability and automatically deliver in-app AI insights we were able to increase benefits and returns for Augmentir customers.
  • 2022 – Augmentir announces the release of True Productivity™ and True Performance™. True Productivity allows industrial organizations to stack rank their largest productivity opportunities across all work processes to focus continuous improvement teams at the highest ROI and True Performance determines the proficiency of every worker at every task or skill enabling truly personalized workforce development investments.
  • 2023 – Augmentir launches Augie™ – the GenAI-powered assistant for industrial work. By incorporating the foundational technology underpinning generative AI tools like ChatGPT, we enhanced our already robust offering of AI insights and analytics. Augie adds to this, improving operational efficiency and supporting today’s less experienced frontline workforce through faster problem-solving, proactive insights, and enhanced decision-making.
  • 2024 – As this year progresses, we have already continued to refine our AI-native solutions and apply user feedback and additional features to best support frontline industrial activities and workers everywhere.
  • 2025 –First to market with industrial AI Agents and a no-code AI Agent Studio purpose-built for frontline operations.
  • 2026 and beyond – Advancing to Agentic Automation, expanding our AI Agent Library and introducing Augie Command Center, Casual AI, and autonomous execution across the platform.

We are deeply involved in applying AI and emerging technologies to manufacturing activities to augment frontline workers, not replace them. Providing enhanced support, access to key knowledge (when and where it does the most good), and improving overall operational efficiency and productivity.

The Future of AI in Manufacturing – The Journey Forward

As we press onward into the future, we at Augmentir are determined to champion the application of AI and smart manufacturing to augment and enhance frontline workers and industrial processes. We will continue to evolve our application of AI and its use cases in manufacturing to help frontline teams and workforces, reinforcing our AI-native pedigree.

The addition of Augie to our existing AI-powered connected worker solution is an important step forward. Augie is a Generative AI assistant that uses enterprise-wide data, provides instant access to relevant information, closes skills gaps with personalized support, offers insights into standard work and skills inventory, and identifies opportunities for continuous improvement. Augie is a result of our dedication to empowering frontline workers, leveraging AI to support manufacturing operations, and giving manufacturing workers better tools to do their jobs safely and more efficiently.

With patented AI-driven insights that digitize and optimize manufacturing workflows, training and development, workforce allocation, and operational excellence, Augmentir is trusted by manufacturing leaders as a industrial transformation partner delivering measurable results across operations. Schedule a live demo today to learn more.

 

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You may have noticed that our website and brand look a little different. Augmentir has a new look, but under the hood, its the same powerful AI that is helping to transform the industrial workforce of the future.

You may have noticed that our website and brand look a little different. Well, that’s because behind the scenes for the past few months, we’ve been under construction (no pun intended).

Augmentir was founded in 2018 with the vision to use AI to empower the industrial frontline workforce to perform at their best. This was a continuation of our rich history – our founding team has been at the forefront of three of the most important of these software technology revolutions in manufacturing over the past three decades – Wonderware Software in 1987, Lighthammer in 1997, and ThingWorx in 2008.

A lot has changed since then. The world we live in today is not the same as it was 4 years ago. And in the last two years, the COVID-19 pandemic has altered the stability of the workforce and drastically magnified some of the industry’s top workforce challenges, which stem from the unprecedented levels of dynamism in the areas of skills diversity, reduced tenure, and increased churn from the “Great Resignation”. Unlike the stable and predictable workforce of the recent past, today companies have to live in the new normal where workers are hard to find, hard to engage, and hard to keep.

These top challenges of today have only reinforced the need for an AI-powered, data-driven approach to empowering frontline workers.

This data-driven era we’re entering into is one of continuous learning and development with tools like remote collaboration and digitized work processes truly integrating frontline workers into the fabric of the business from a collaboration standpoint whereas they may have been overlooked before.

Augmentir’s AI-powered connected worker platform provides the tools to not only survive in this new normal but to thrive.

You can’t build a truly modern, connected workforce without AI

The term “connected worker” has become a recent buzzword in the manufacturing world, and is now considered a tool that the new generation of workers expect to work with. But true connected work means using AI to allow frontline workers to have access to internal and external resources that are appropriate for when and how they need them.

Augmentir isn’t your typical connected worker platform. Our platform was built from the ground up on an AI foundation. AI algorithms are ideal for analyzing large amounts of data collected from a connected workforce. AI can detect patterns, find outliers, cleanse data and find correlations and patterns that can be used to identify opportunities for improvement and create a data-driven environment that supports continuous learning and performance support. Our connected worker platform utilizes AI to help train, guide, and support today’s frontline workers in a dynamic workforce by combining digital work instructions, remote collaboration, continuous development and advanced on-the-job training capabilities.

This approach aligns perfectly with the dynamic, changing nature of today’s workforce, and is ideally suited to achieve and sustain effective on-the-job performance.

As the world’s only AI-powered connected worker platform, we decided it was time to refresh our brand identity to accentuate our strongest feature and the thing that makes Augmentir unique – AI. We’re still the same AI-native connected worker platform that you know – just with a new look.

Learn how connected worker technology can help you standardize and digitize layered process audits for improved accuracy and better quality results.

Digitized Layered Process Audits (LPAs) are important in manufacturing for establishing and enhancing process standardization, quality management, multi-level workforce engagement, risk mitigation, and quality standards compliance. The primary function of a Layered Process Audit is to focus on observing and validating how products are made to ensure process and product quality. This effectively protects manufacturers and frontline manufacturing personnel from defects and process issues before they can do any damage.

digital layered process audits

Many crucial manufacturing processes are still carried out using outdated pen-and-paper methods; and as the industry continues to evolve, digitization is essential to remain competitive and maintain proper quality and safety standards. Layered Process Audits are no exception, with digitized layered process audits now a necessity, rather than a luxury, for organizations looking to keep pace, elevate their audit processes, and meet the demands of the evolving industry.

Learn more about how to streamline LPAs with connected worker technology, implement digital LPAs, and the benefits of AI-powered analytics for digitized LPAs and overall quality management excellence in manufacturing below.

Benefits of a Digitized Layered Process Audit

Connected worker platforms allow manufacturers to replace paper-based audit forms (like a layered process audit) with digital checklists that can be accessed and completed on mobile devices, allowing for:

  • Standardized audit formats and best practices across audit layers
  • Real-time data collection and improved audit tracking
  • Mobile access to information and knowledge including relevant documents, procedures, and historical data
  • Automated audit scheduling and notifications for consistent audit frequency across layers and reduced administrative burden
  • Real-time issue reporting and escalation for faster response and issue resolution
  • Improved data analytics and reporting to generate and apply insights as well as identify recurring issues and root causes
  • Overall system integrations with things like ERP, MES, and CMMS

These abilities offer a significant boost to manufacturers in terms of operational efficiency, risk mitigation, workforce development, and cost reduction.

Implementing Digital Layered Process Audits

Manufacturers can digitize LPAs and streamline their quality management processes through AI-powered connected worker technologies, improving data quality and driving faster, more effective quality improvements across the organization.

layered process audit framework

Implementing digital Layered Process Audits (LPAs) involves several steps, from selecting the right platform to engaging the team and ensuring proper integration with existing systems. Below is a step-by-step guide to implementing digital LPAs effectively:

1. Choose the right Digital LPA Platform

Research and select a digital LPA platform that meets your organization’s needs. Consider factors like:

  • Ease of use (especially for mobile devices)
  • Customizability (to fit your audit checklist and process requirements)
  • Integration with existing systems (e.g., ERP, quality management systems)
  • Reporting and analytics capabilities
  • Scalability for future needs

2. Develop and Digitize Audit Checklists

  • Standardize Audit Checklists: Create or review the audit checklists for each layer of the audit process. Ensure they are aligned with your goals, operational requirements, and industry standards (e.g., ISO, IATF).
  • Digitize the Checklists: Input these checklists into the digital platform. Ensure that they are tailored to different levels of the audit process, from shop floor employees to higher-level management.
  • Customize Alerts and Criteria: Set up criteria for success/failure and alerts for non-conformance. This can include conditional triggers where a failed audit automatically prompts corrective actions.

digitized layered process audit LPA with augmentir quality control checklist

3. Integrate with Other Systems

  • Link to Quality Management Systems (QMS): Integrate the LPA platform with your existing QMS, ERP, or other relevant systems to streamline data sharing and analysis.
  • Automate Corrective Action Processes: Ensure that non-conformance findings in the audit automatically trigger corrective action workflows, and link them to task management or follow-up procedures.

4. Monitor, Analyze, and Improve

  • Track Real-time Results: Use the platform’s dashboards and analytics features to monitor performance metrics, such as audit completion rates, non-conformance trends, and the time taken to close corrective actions.
  • Conduct Regular Reviews: Hold periodic review meetings with the audit team and management to discuss audit findings and trends. Use this information to drive continuous improvement in processes.
  • Make Adjustments: Based on the insights from the audits, adjust the audit checklists, procedures, and corrective action plans as needed.

5. Foster a Culture of Continuous Improvement

  • Encourage Engagement: Foster a culture where employees see the value in LPAs and actively participate in the process. Offer incentives or recognition for high levels of engagement or process improvements resulting from audits.
  • Regularly Update the System: Keep the digital platform and audit processes updated to reflect changes in standards, regulations, or internal processes.
  • Leverage Advanced Analytics: Over time, use advanced analytics and machine learning (if available) to predict potential non-conformance areas and further streamline corrective actions.

By following these steps, you can effectively implement a digital Layered Process Audit system that enhances visibility, accountability, and process control across your organization.

Driving Continuous Quality Improvement with Digitized LPAs

Excellence in quality management drives success in manufacturing. Digitizing and updating old processes with AI, connected worker platforms, and even simple digital layered process audit software allows manufacturing organizations to better identify and prevent defects at their source and protect against rework, customer complaints, costly product recalls, and reputational damage.

Recent innovations in AI technology and applications caused an explosion of growth all across the world and in various industries. Manufacturing is uniquely situated to adopt these technologies for massive growth. One valuable use case is the use of AI to optimize quality management, specifically to optimize audit processes like LPAs for drastically improved results and insights that simply weren’t possible previously.

AI analytics combined with connected worker technologies digitize and streamline layered process audits allowing manufacturers to capitalize on shop floor data data capture for:

  • Trend analysis across different audit layers, departments, and locations
  • Automated population of audit forms with relevant data
  • Seamless creation of digital work instructions from audit findings
  • Application of cobots, generative AI assistants, or AI copilot technologies to support auditors and workers alike.

But this does not stop there, according to a study by McKinsey & Company, companies that prioritize quality management achieve higher levels of employee engagement. Engaged employees are more likely to be committed to producing high-quality products, resulting in increased productivity and customer satisfaction. The addition of AI to capitalize on connected worker data and feedback to generate insights, support enhanced decision-making, and create better processes offers manufacturers a path forward into the future with a better-equipped and supported frontline workforce.

Interested in learning more?

If you’d like to learn more about how Augmentir streamlines and optimizes quality management processes like digital layered process audits and more, schedule a demo with one of our produce experts.

 

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