With the right approach to digitalization technologies, manufacturers can not only achieve their connected worker operational efficiency goals, but can also take an increasingly proactive and predictive approach to worker safety.
Manufacturers across industries are implementing new technologies to connect, engage and empower their workforce. They’re enabling seamless voice, video and data communications everywhere on campus, equipping workers with connected tools, and providing instant access to the necessary digital information from handheld devices at the point of decisions and actions — including enriched data and immersive augmented and virtual reality content to enhance worker knowledge and learning.
Manufacturers are taking these steps because they realize that a connected workforce is essential to achieve the levels of efficiency, flexibility and productivity needed to meet operational and optimization objectives — especially as worker shortages, skills gaps, retention issues and difficulty attracting new talent continue to strain operations.
What manufacturers may not realize is that the same digitalization foundation that underpins these initiatives — pervasive connectivity, data, analytics, industrial edge, and use case applications —also empowers them to build on and extend their current safe workplace initiatives.
Worker safety remains top of mind for every manufacturer. In 2021, the Eurostat revealed that there were 2.9 million non-fatal industrial accidents reported in the European Union, with 540,000 occurring in manufacturing. Every year in the EU there are an average of 1.76 fatalities per 100,000 workers1.
Connected workers are better protected workers
In many cases, worker safety enhancements are natural extensions of connected worker initiatives. For example, with communications available campus-wide, workers can use push-to-talk and push-to-video solutions to collaborate from any plant location, and the entire enterprise can access asset data and intelligence.
The same digitalization infrastructure also supports safety-critical communications and increased situational awareness for safety-related event identification, response and prediction. Now all workers, including those working alone in hazardous or remote location, are securely and reliably connected so they can identify safety issues or request assistance. And workers can instantly notify, guide and support one another before, during and after incidents.
Geo-positioning technologies are another good example. With highly accurate asset tracking and positioning technologies, everyone can work more efficiently. When that positioning information is combined with data from intelligent IoT sensors, real-time alerts and navigational assistance technologies, workers have timely visual and audio cues that dramatically enhance their situational awareness. They’re instantly aware of risks such as approaching vehicles or changing environmental conditions so they can make informed decisions, and they can quickly find the best route to safe zones when necessary. Adding AI and machine learning technologies that provide predictive information and intelligence gives unprecedented insight into workplace environments, so risks can be mitigated before safety incidents occur.
There are also opportunities to expand on AR and VR training programs. Now workers can access digital drawings, work instructions, safety procedures and other rich content through smart glasses, tablets and handhelds to help them prevent, and quickly respond to, safety incidents anywhere on their industrial site.
These are just a few examples of the potential to incrementally improve worker safety using technologies available today:
- Generative AI solutions to enable real-time contextual communications between workers and machines using natural human language
- Drones and autonomous robots to inspect hazardous areas, assess incident severity and deliver emergency equipment to remote or endangered workers
- Geofencing to virtually identify, isolate and limit access to hazardous areas
- Digital twins to safely visualize changes, predict outcomes and optimize networks and operations plant-wide
- Camera-based tracking to gain a high-level view of industrial sites for safety analysis
- Purpose-built industrial devices, cameras and smart PPE, including Ex-certified handhelds, to connect and protect workers in dangerous environments
A single digitalization platform underpins all opportunities
To simultaneously achieve connected worker and safety goals, manufacturers must take a new approach to technology — one that allows them to continue leveraging their legacy niche solutions while evolving to an ecosystem neutral, standardized and multi-purpose digitalization platform that supports their objectives plant-wide and scales to support their long-term digitalization journey.
For maximum business benefits, the digitalization platform should provide 4G/5G private wireless and Wi-Fi connectivity as well as industrial edge processing, cutting-edge applications and ruggedized devices. This combination gives manufacturers a cohesive, secure and scalable foundation that supports connected worker, worker safety and other aspects of their overall Industry 4.0 strategy. As new use cases are added to the digitalization platform, the ROI multiplies.
The platform must reside on-premises and seamlessly integrate with existing industrial automation networks, operational systems and technologies; it must be inherently secure, with optimum performance and reliability, and the support for redundant and alternative communications channels that are essential for comprehensive worker safety.
Start now, start small, continuously improve
The road to plant-wide digitalization is far closer than many organizations realize. The key is to start small, focusing on one or two use cases, then gradually scale deployments and use cases. This highly controlled and stepped approach allows thorough validation of integration with existing systems, worker acceptance and use case effectiveness so refinements can be made before site-wide and multi-site rollouts. It also allows manufacturers to take full advantage of the ecosystem of technology experts who have joined forces to simplify the journey to connected workers and safer workplaces.
For more information, visit dac.nokia.com/industry/worker-safety
To learn more download the new eBook: Discover the impact of digitalization for improving Worker Safety in manufacturing
1 Destatis, 2023.
Tom Richter is head of vertical industries for Nokia, where he supports the design and specification of tailored network solutions based on the specific vertical requirements of manufacturing companies. With more than 25 years of experience in sales, marketing and commercial management and an understanding of the underlying technologies he provides support for the Nokia sales colleagues to serve this new customer segment.
For more articles like this, visit our Digital Transformation channel.