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    Enabling the Manufacturing Workforce in the Factory of the Future

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    1Industry 4.0 2Enabling technologies 3Impact & challenges 4 PeopleStrategy 5 Conclusion & Takeaways


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    • Personal experience implementing change on the manufacturing floor

    • Exposure to advanced manufacturing technology

    • Passionate about leadership and technology


    Why I’m here ?

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    Industrial Revolutions

    1 st 2 nd 3 rd 4 th

    The first industrial revolution used water and steam power to mechanize production

    Steam Electricity Computing Smart Manufacturing

    The second industrial revolution used electrical power to create mass production

    The third industrial revolution used electronics and computers to automate production

    The fourth industrial revolution marries advanced technologies with connectivity to create intelligent manufacturing systems

    1784 1870 1960 Today (?)

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    Everything gets Smart

    Smart Phone

    Smart Home

    Smart Car

    Smart Factory

    The factory of the future will be “smart”

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    Smart Factory • Supplies products with high value added • Flexible enough to respond to swiftly

    changing market demand • Fully embraces digitalized production

    processes • Exploits the potential of modern

    production technologies ( IT/OT) • Carefully handles energy and materials • Human centric vs task centric

    Source: http://www.madedifferent.be/en/what-factory-future-40

    Smart Factory

    Smart factory combine mass production efficiency with custom manufacturing ( on demand) and optimize the supply chain in real time

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    Smart Factory

    Industry 4.0 is affecting the complete lifecycle Av: Prof. Dr. Detlef Zühlke, Scientific Director, German Research Center for Artificial Intelligence, Innovative Factory systems

    HR Too!

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    Enabling Technologies

    Virtual reality



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    Enabling Technologies

    Virtual reality



    Virtual reality

    Senses of Smart Factory


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    A network of Internet connected devices , equipment, machines that are able to collect and exchange data to improve manufacturing and industrial processes

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    Augmented reality

    overlays information and virtual objects on real-world scenes in real-time.

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    Virtual reality & simulation

    Create ,test, build, operate and service products and processes in a virtual environment

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    Enabling Technologies

    Virtual reality


    AI Muscles of Smart Factory



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    robots capable to interact with each other and cooperate with humans without the need of safety restrictions

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    Additive Manufacturing

    Manufacturing objects one fine layer at a time from a 3D model

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    Incorruptible digital ledger of economic transactions that can be programmed to record not just financial transactions but virtually everything of value

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    Enabling Technologies

    Virtual reality



    Brain of Smart Factory

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    Cloud Computing

    Access information from anywhere, anytime , on any device

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    Big Data Analytics

    The collection and comprehensive evaluation of large volume of data from many different sources to uncover information including hidden patterns, unknown correlations

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    AI / ML

    AI works by combining large amounts of data with fast, iterative processing and intelligent algorithms, allowing the software to learn automatically from patterns or features in the data.

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    Industry 4.0 Benefits

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    Industry 4.0 offers opportunities through a smart combination of:

    Digitalization Connectivity Technologies (IT &OT)

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    All businesses are made up of PEOPLE

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    Industry 4.0 Impact to Job market ▪ It will increase the need for certain


    – Automation Engineer

    – IT solutions architect

    • It will create new jobs

    – Robot coordinator

    – Industrial data scientist

    – Digital twin Engineer

    – Predictive Maintenance analyst

    – Etc…

    Industry 4.0 technologies drive link

    between workers, equipment, software,

    and machines

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    Estimated # jobs directly created by Industry 4.0

    Driving growth and directly creating 900K new industry 4.0 jobs by 2025

    Jobs along all functions will be affected by Advanced technologies

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    Skills Required for Advanced Manufacturing

    Social skills • Coordination, persuasion ,

    team work , communication, Etc..

    Resource Management skills • Time management , work

    ethic , priority development , courage to ask questions, etc

    General Skills Technical Skills

    Technical Skills • Programming , Design and

    analysis , trouble shooting , Quality Control analysis, etc..

    Learning • Critical thinking ,


    Complex problem solving

    Judgment and decision making


    Adaptive Skills

    Basic Complex skills

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    Perfect Storm for US manufacturing Strong Economic growth

    Baby Boomers retiring ( 10,000/ day)

    Misperceptions of manufacturing jobs

    Stiff competition from the tech sector for younger workers

    STEM education is inadequate for today’s shop floor

    Opioid addiction diminish effective pool of workers

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    Manufacturing Skill gap Studies show that the skill shortage is expanding

    2.0 M 2.4 M

    2025 2028

    Positions unfilled Source: BLS Data, OEM (Oxford Economics Model), Deloitte and Manufacturing Institute skills research initiative.



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    Industry 4.0 People strategy

    Retain Retrain Recruit

    • Give and request feedback • Invest in employee career

    development and re-skilling • Workplace improvement • Flexible work schedule • Paid leave time • Improved benefits package

    • Foster a positive perspective on change

    • Recognize the adult leaning model • Leverage digital technologies ( Online

    competency-based learning programs,)

    • Co- mentoring program

    • Focus on capabilities, rather than qualifications

    • Partnerships with tech programs/schools and community college

    • Leverage digital manufacturing to attract

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    Why do we have to continuously learn and adapt?

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    Information Overload

    Human Life Spans

    Life expectancy

    35 years

    Life expectancy

    45 years Life expectancy

    80 years…


    Roman Dark Ages

    Renaissance Industrial


    Technological Revolution

    Computer Age

    Information Age

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    Take Away

    1 Being competitive in the modern fast-paced business environment requires applying industry best practices in advanced manufacturing technologies , product development processes and organizational culture to the business

    2 Knowing what is Industry 4.0, and how it will affect the industry, is only half the battle. Are you benchmarking, reaching out to industry peers? Do you have a digital transformation strategy ?

    Are you meeting with your industry partners to answer the question 5 years out ? What do you see ?

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    Take Away

    Last but not least, it will have to go beyond teaching the technical skills required by today’s manufacturing world and technologies and teach the adaptive skills that will be needed tomorrow instead

    3 The challenge is too complex for a silver bullet solution. It requires a multi-pronged approach ▪ Making the industry more attractive to the new generation ▪ Addressing continual reskilling of workforce. ▪ Providing better education and training ▪ Developing a digital transformation strategy and new workforce roles


    Do you have partnerships , have you spoken with local universities , do you have intern programs ? How are you communicating about you company ?

    Look at your training offering , where are the gaps in your training programs and hiring pool ? Are you looking at those type of skills ?

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