by Gary Mintchell | May 4, 2026 | Operations Management, Software, Workforce
Digital transformation initiatives are all the rage—at least in the marketing release system. I remain amazed that after all the released products and articles I’ve written the software layer of PLM and MES remain under utilized. One recent concern discussed in two recent interviews focuses on frontline workers and their supervisors.
The same situation exists that I confronted 50 years ago in an early role as data manager for a manufacturing company—no appropriate work is accomplished without reliable, easily assimilate-able, and clear instructions make it to the people doing the work.
In the standard words of reporting, I caught up with Garth Coleman, CEO of Canvas Envision, at the recent Aras Community Event in Miami, FL. The was the first of my two conversations on the topic.
He told me that while over the last few years, many industries have become dynamic, data-rich, and modernized, factory floor instructions are still largely outdated with PDFs, screenshots, and text-heavy documents that are now increasingly stale.
Just as part of my job years ago, manufacturers are still struggling to align as-built with as-designed.
He argues the shift here demands interactive, model-based instructions where teams adopt systems in real-time, creating a continuous loop for operations, rather than the other way around.
Canvas Envision features these cutting-edge technologies:
- No-Code Workflows: Allowing users to build and modify instructions without the need for IT involvement.
- CAD Fidelity: Ensuring that instructions are always up-to-date with design changes through native CAD visualization.
- AI Assistance: Automating the generation of complex views and lists with Evie, the integrated AI assistant.
- Gadgets: Providing ready-to-use components like checklists and data capture.
- Integration and Flexibility: Seamlessly connecting with enterprise systems (PLM, MES) and offering flexible deployment options (SaaS or self-hosted).
Until you close that final loop aligning as-built with as-designed in a 360-degree loop, everything is only data.
by Gary Mintchell | Mar 24, 2026 | Education, Workforce
The press release was tempting—a survey showed the most sought skills among manufacturing people. But…I’d never heard of the company called Wiingy. I wondered, who are Wiingy and how did they execute the survey?
Turns out the company is a marketplace for tutors for myriad subjects. It’s an interesting place to check out.
The study draws from over 6.7 million monthly searches from Google Keyword Planner and Ahrefs, showing strong learning intent across beginner, intermediate, and advanced levels. Technology leads the way, making up 33% of total searches, with high interest in skills like Python, AI, and Data Science. Yet, there’s also a growing pursuit of personal and creative skills like piano, swimming, and cooking. Together, these trends show that Americans are not just chasing career growth; they’re seeking balance between professional advancement and personal fulfillment in an evolving, skills-driven world.
The 25 Most-Learned Skills in America: A Data-Driven Report on the Future of Education (2025) By Wiingy Research Team.
It’s almost like Covid redux—the top searched skill was cooking.
Relevant to manufacturing, the top searched skills were:
- Project Management
- AI
- Cybersecurity
- Python
- AI Tools
- Data Science
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by Gary Mintchell | Mar 18, 2026 | Education, Robots, Workforce
Here’s a free learning event in Reno concerning the value of robotics for expanding your manufacturing productivity.
As Northern Nevada’s manufacturing sector continues its rapid expansion, the region’s employers are confronting a growing challenge: a labor market that has nearly run out of slack. OnRobot will host the “Build your Automation Roadmap” event in Reno on April 9th, bringing practical automation solutions directly to the region’s manufacturing community.
The free, in-person event is designed for manufacturers in sectors such as metal fabrication, CNC machining, electronics, aerospace, food & beverage, and industrial equipment manufacturing – industries that form the backbone of the Reno manufacturing economy and are among the hardest hit by ongoing labor shortages.
Event Snapshot:
Build Your Automation Roadmap: Industrial Robots + Tooling
A hands-on event featuring live FANUC robot demonstrations, expert-led workshops, and real-world automation use cases.
April 9th, 2026, 12:00pm–4:00pm PT
Grand Sierra Resort, 2500 East 2nd St, Reno, NV
Northern Nevada’s manufacturing sector has grown faster than its available workforce can keep pace with unemployment rates at just 4.0%, near the lowest levels on record – leaving manufacturers with a shrinking pool of available workers even as industrial demand continues to grow.
A recent report from the University of Nevada, Reno, commissioned by the Nevada Office of Workforce Innovation, identified workforce gaps across every regional economic development authority in the state, with fabricated metal manufacturing, precision machining, and electronics among the most acutely affected sectors in the Reno area.
“Northern Nevada has become one of the most dynamic manufacturing regions in the country, but that growth is creating real pressure on employers who simply can’t hire fast enough to keep up,” said Kristian Hulgard, General Manager, Americas, at OnRobot. “Automation isn’t a future consideration for manufacturers here, it’s an immediate operational need. This event is about giving the region’s manufacturers a clear, practical path forward.”
At the event, attendees will see live demonstrations of FANUC robots equipped with OnRobot end-of-arm tooling for common applications such as machine tending, material handling, assembly, packaging, and quality inspection. Automation experts, that help manufacturers move from curiosity to confident implementation, will be on hand to share real-world experience in robotics, tooling, and integration.
Featured Speakers and Sessions:
Kristian Hulgard, General Manager, Americas, OnRobot – Opening keynote on macrotrends affecting U.S. automation growth, why adoption is accelerating across manufacturing, and what it means for Nevada operations.
Brian La Plante, District Manager, FANUC America – Live demonstrations of FANUC robots, identifying the practical approach to the automation journey.
Marc Magarin, President and Co-Founder, Nevatio Engineering – Learn how the right components, sourcing strategy, and distribution support keep automation projects on track.
Registration incl. lunch is free, but space is limited.
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by Gary Mintchell | Jan 27, 2026 | Generative AI, Workforce
Another survey of manufacturing business leaders regarding applying AI in their operations and availability of a skilled workforce to apply it.
Revalize, a worldwide leader in CPQ, PLM, and CAD software solutions for manufacturers, released new research around the state of AI and smart technology adoption in the manufacturing sector. Despite ongoing economic uncertainty, the report finds that technology investment continues to surge, prioritizing AI and automation, yet many companies are struggling to find talent with the right skillsets to implement and deploy the technology effectively. Manufacturers must focus on streamlining systems and upskilling workers to leverage emerging AI opportunities and fully realize the return on these investments.
The report, Smart Manufacturing 2026: Agile Leaders Confront the AI Skills Gap, features data gathered from a survey of 500 business leaders in select manufacturing fields across the United States, Germany, Austria, and Switzerland. The research reveals companies are investing in new technologies, but many are starting to face the reality that their workforce might not be ready for it.
Key findings include:
- Technology Investments Continue to Rise: 77% of manufacturing leaders report increased software budgets over the past 12 months, up from 70% the year prior, signaling sustained momentum behind digital transformation. Additionally, 93% of manufacturing leaders plan to utilize new technologies, tools, or software this year.
- Holistic AI Adoption is Lagging Despite Lofty Goals: While 56% of manufacturers reported having implemented AI in select areas, only 10% said the technology was fully integrated across their operations, illuminating a critical gap in execution.
- The U.S. Has the Highest Demand for AI Skills: U.S. manufacturers lead investment in AI-driven and human-centric Industry 5.0 technologies, creating the highest demand for AI skills among all countries surveyed. As a result, 44% of U.S. teams cited a need for AI expertise, 16% higher than other regions.
- Industry 5.0 Confidence Remains High, but Realism Grows: 84% of manufacturers feel prepared to adopt and leverage Industry 5.0 technologies, a slight decline from last year, reflecting a more realistic understanding of the integration, data, skill, and workforce capabilities required for success.
“AI and automation are transforming the manufacturing sector, but without serious investment in workforce training to leverage these technologies, initiatives fall short of expectations,” said Mike Sabin, CEO of Revalize. “The industry’s continued technology investments must be matched by a commitment to upskilling talent through both internal programs and external academic partnerships. I foresee 2026 as a pivotal turning point where manufacturers will either move beyond AI hype and take the necessary steps to bridge the gap between investment and readiness or fall behind as competitors move faster toward Industry 5.0.”
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by Gary Mintchell | Oct 23, 2025 | Productivity, Workforce
Articles about a worker shortage due to Boomer retirements have been a staple of trade magazine editorial ever since I became an editor in 1998. Some twenty-seven years later, those articles and news releases keep coming.
The concomitant problem is how to bring new people in. Apprenticeship programs went out the window with World War II. Businesses and manufacturers began expecting the education system to supply appropriately skilled workers. This was not going to happen despite education systems becoming increasingly industrialized. They taught basic math. Taught kids how to sit still and follow directions. Taught them to show up every day at the required location.
We need more.
It’s taken me some thought to place this new product from Derek Crager, Founder & CEO of Practical AI.
There is irony here, in that Crager touts himself as developer of an award-winning training program at Amazon—yes, the place that thinks it can replace its workers with robots. But, we will go beyond that thought for now.
I’ve not read the book, but he has also released a new book, Human First AI.
Crager says the real cost is downtime, rework, and attrition. He continues, It isn’t just a staffing problem—it’s an OEE problem. Every knowledge gap shows up in the metrics leaders actually manage: MTTR, FPY, scrap, rework, and yes, attrition. Ask any maintenance manager: the fastest way to lose a promising hire is to strand them without support on a tough job at 2 a.m. We send people to training, hand them SOPs, and hope they remember when it counts. But memory fails—especially under pressure.
His solution? Just-in-time guidance—the right step at the exact moment of need, while hands are on the task. When a technician can ask and do in the same breath, training becomes throughput. That’s the difference between teaching a concept and multiplying your best expert across every line and shift.
He called on his experience at Amazon to develop something called Pocket Mentor: A Phone Call to Your Best Expert. This is a hands-free, eyes-free mentor your team reaches by phone, anytime, on the floor or in the field. No app. No Wi-Fi. No passwords. Just tap & say, “Talk me through it” — and we will.
Here’s how it works:
- Capture once. We sit with your best people and harvest SOPs, changeovers, fault trees, “what-if” branches, and tribal tricks—the real decision trees pros use when the line’s on fire.
- Validate and govern. Content is approved by your SMEs and version-controlled with human-in-the-loop QA. Your source knowledge stays in a secure, governed box; people approve changes before they go live.
- Guide in the flow of work. A tech calls in, we ask two clarifying questions (model, symptom), then deliver step-by-step voice guidance they can follow while working—hands-free — eyes-free.
- Optional enterprise integrations. We can use your digital-twin/IoT signals today (enterprise integration) to pre-fill context—e.g., “Given Code 47 and 200 service hours, here’s the fastest fix; want me to talk you through it?”
He cites this pattern of stats.
- Up to 80% faster onboarding—because new hires can “tap & say” from day one instead of waiting for a veteran.
- ~30% reduction in downtime/rework—because the right step shows up at the right time, not after the post-mortem.
- ~53% lower early attrition—because nobody wants to feel alone on the line; support drives retention.
- 30× impact vs. traditional training—because we replace recall with real-time execution.
- 0 extra staffing to scale coaching—your best employee effectively becomes 20 or 50 virtual coaches, every shift.
Most project managers agree that you should start with a specific pilot, prove the system, then scale it out. Crager offers a few suggestions.
- Pick a chronic stopper. The two or three faults that always cause headaches (and overtime).
- Harvest the fix. Sit down with your A-team and capture the real-world fix path—model variants, hard-won “gotchas,” and the restart checklist nobody remembers at 3 a.m.
- Go live by phone. Give your night shift a number to call. Let them say, “Talk me through it.”
- Measure MTTR for 30 days. Compare to your baseline. Then expand to changeovers, start-of-shift checks, and training-intensive stations.
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by Gary Mintchell | Sep 29, 2025 | Productivity, Workforce
Note: I had an allergy attack following my California trip that wiped me out for a few days last week. Now trying to catch up with a number of thoughts.
’Tis the season of surveys and reports.
Actually, that season has become about as year-around as Christmas and Halloween. Once the province of pharmaceuticals, companies commission surveys and report on the ones that support their place in the market.
Not to be entirely cynical—technology supporting the front-line worker has been burgeoning over the past few years. Perhaps this was accelerated by Covid pandemic increasing remote workers? I don’t know.
The other interesting tidbit concerns Zebra Technologies, sponsor of this survey (companies call it research, but given my grad school courses, I balk at that description), has grown through some acquisitions from the company I knew (and sold a couple products) in the 90s.
Oh, and they had to throw AI into the mix. It’s up to you to figure out what they mean by that.
Zebra Technologies Corp. announced new research in collaboration with Oxford Economics. The study showcases how improving frontline workflows with modern technologies like AI, automation, and data improves profitability and enhances the customer experience.
Retailers reported a 21% improvement in customer satisfaction, manufacturers cited a 19% increase in employee productivity, and T&L leaders reported a 21% increase in productivity with better workflows. In addition, the study indicates AI investments help organizations achieve real-time visibility, generate actionable insights and improve efficiency.
Companies surveyed said they were using (unspecified) AI to address loss prevention, risk detection, inventory optimization, inventory management, demand forecasting, and predictive analytics—all typical machine learning technologies that have been around for a while.
They also noted using tools that have been around for years, although greatly improved since I sold and installed them in the 90s—RFID and machine vision.
The news release touts Zebra’s new brand narrative, “Better Every Day” affirming the company’s commitment to empower organizations with automation and AI to create new ways of working that make everyday life better.
