While walking the floor at GlassBuild this year, I noticed that automation is the new direction that all the top equipment companies are focusing upon when it comes to new equipment development. This comes as no surprise, as the lack of reliable labor continues to be a major problem when it comes to staffing needs on the production floor. But there is one key aspect that will hold back the promises of automation, and that is the lack of high-tech savvy employees to meet the new demands created by the amazing promises of automation. It reminds me of the movie, “The Wizard of Oz.” Dorothy and the gang were so fearful and in awe of the great and powerful Wizard of Oz until it was revealed that the Wizard was just a machine being controlled by a man behind a curtain. When he realized that he was busted, the Wizard shouted, “Pay no attention to the man behind the curtain!”
Well in the case of automated machinery for the door and window industry, we do need to pay attention to the man behind the curtain! There is a significant talent gap, especially in areas like mechanical, electrical, software engineering, artificial intelligence (AI) and cybersecurity in the current stock of employees versus what is needed to operate and maintain sophisticated, automated machinery. There is a shortage of skilled workers with the necessary skills to implement, manage, and maintain these new technologies, which has led to a demand for reskilling and upskilling the current workforce. So, what I am saying is that, while automation holds the promise of reducing the number of workers required on the plant floor, it is also significantly raising the skill level of the workers required on the plant floor, and this needs to be taken into consideration when taking the plunge to acquire automated machinery.
Therefore, companies investing in automation need to also focus on three key areas:
1. Upskilling and reskilling their existing employees to fill the technology gaps, rather than just hiring new talent. If your company does not offer tuition reimbursement, then it should be something to consider immediately to assist current employees in obtaining the advanced education needed to deal with highly sophisticated machinery. Hiring new talent may be necessary in the beginning to quickly address the technology gap, but investing in the upskilling of your current employees will reap long term benefits to your organization. Servicing automated machines requires a combination of technical skills, including mechanical, electrical, and programming knowledge, and soft skills, such as problem-solving, communication and adaptability. Key technical skills include proficiency with tools, understanding systems like pneumatics and hydraulics, and the ability to read blueprints. Strong analytical and problem-solving abilities are essential for diagnosing and fixing issues quickly, while soft skills ensure effective collaboration and communication with others.
2. Emphasis on continuous learning. The value of traditional degrees is not as important as prioritizing practical skills and continuous learning. Perhaps the companies that are selling the latest automation can assist with technical courses for their clients to enable them to keep up with technological demand where traditional academia may be lagging. Yes, it is happening that fast. Analytical skills of your technical employees must also be developed. The ability to analyze data and think critically under pressure is vital for understanding system performance and resolving complex issues. Your maintenance people must also be top notch. Mechanical and electrical knowledge: A strong understanding of motors, drives, pneumatics, hydraulics and other mechanical/electrical components is crucial for maintenance and repair. Communication skills are also key. Clear communication is necessary to collaborate with team members, document issues, and explain technical information to others.
3. Maintaining manual backup systems. Be careful when investing in automated systems for which there are no manual back up processes available. If the robots go down, and the “you know what” hits the fan, can you roll out a manual backup system to get orders out the door until parts are obtained and repairs are made? It may take some additional workers and a few extra hours, but at the end of the day you are loading trucks and getting doors and windows out to your customers. I know one company that was able to continue operating this way when their automated system was hit by a cyber-attack. They were able to keep operating while repairing the IT infrastructure and avoided paying a ransom.
So, as your company is considering the purchase of multi-million-dollar automated equipment, do not forget to also plan for and budget for a serious upgrade of the skill level of the employees that you will rely upon daily to operate and maintain your new investment. In other words, yes, do “Pay attention to the man behind the curtain!
Great article Jim!