SYSCON PlantStar Blog

Bridging the Skills Gap & Empowering a Modern Workforce with MES

Written by David Crowley | Jan 10, 2025 9:30:00 PM

The need to bridge a widening skills gap and attract and retain a modern workforce poses a major challenge for manufacturers. With an estimated 3.8 million manufacturing job openings projected between 2024 and 2033 (and nearly 1.9 million of those potentially remaining unfilled due to the skills gap and applicant shortages), the urgency to act has never been greater. Manufacturers must adapt not only to rapid technological advancements but also to the evolving expectations of a younger, more tech-savvy workforce. This article explores how manufacturing execution systems (MES) can help bridge these gaps, support lean manufacturing principles, and foster a modern, engaged workforce.

Addressing Skills & Applicant Gaps with Technology

In this dynamic environment, technology emerges as a powerful tool. It can not only increase efficiency and productivity but also play a crucial role in attracting and retaining skilled talent. By automating repetitive tasks, providing real-time data insights, and creating a more connected and collaborative work environment, technology can empower employees, improve job satisfaction, and enhance overall competitiveness.

Streamline Operations

Technological advancements in manufacturing are outpacing workforce capabilities, creating a need for systems that simplify complex processes and enhance productivity. Manufacturing execution systems (MES) meet this need by automating tasks, reducing downtime, and providing real-time production and process insights, allowing manufacturers to operate efficiently despite workforce limitations.

A robust MES provides a variety of features that streamline operations, such as operator tracking, automated job scheduling, labeling and barcoding, remote monitoring with instant notifications, and ERP integration. These kinds of features can enable manufacturers to overcome labor shortages with actionable, real-time insights.

Reduce Manual Interventions

Automating tasks like job scheduling, data collection, and quality checks frees up valuable time for employees. Instead of manually recording data or adjusting equipment settings, workers can focus on more strategic tasks like problem-solving, process improvement, and innovation.

Monitor Operations Remotely

An MES enables supervisors to monitor operations from anywhere, receiving instant alerts when anomalies arise. This allows employees to respond faster, reducing waste. When equipment malfunctions or processes deviate from normal parameters, instant notifications allow manufacturers to minimize downtime by performing proactive maintenance. This not only improves efficiency but also enhances safety by alerting workers to potential hazards.

Collect & Analyze Data in Real Time

MES solutions capture and analyze data from various sources. This real-time data provides actionable insights into production bottlenecks, inefficiencies, and areas for improvement. By identifying and addressing these issues proactively, manufacturers can optimize their production processes and reduce overall costs.

Support Lean Manufacturing

Smart technologies, used correctly, have really enhanced or accelerated companies’ ability to implement lean manufacturing and drive improvement in a big way. — Bob Argyle, chief customer officer at Leading2Lean

Lean manufacturing, which focuses on maximizing value while minimizing waste, is a vital tool for increasing manufacturing efficiency. Innovations like MES and the internet of things have enabled manufacturers to take lean practices to a new level, driving unprecedented productivity and waste reduction while creating opportunities for continuous optimization. Below are some of the ways MES is helping manufacturers quickly identify and eliminate sources of waste.

  • Real-time dashboards enable operators to optimize machine usage.
  • Employee schedules and performance can be easily tracked and combined with supply chain, demand, and materials data, allowing managers to optimize labor and improve productivity.
  • Real-time machine monitoring can enable predictive maintenance programs, which can eliminate unnecessary maintenance efforts, prevent unexpected failures and downtime, and extend equipment life.
  • Process journals that track maintenance histories, equipment issues, and resolutions better enable manufacturers to continuously improve equipment care.
  • Scrap reporting helps identify sources of materials waste.
  • Instant alerts allow employees to address errors, delays, and bottlenecks as early as possible to minimize waste.
  • ERP integration breaks down data silos to unify supply chain management, inventory, and order processing for just-in-time manufacturing.

Attract Top Talent

Technology plays an important role in shaping the future of workforce development. It can act as a magnet in both attracting and retaining skilled individuals. —Deliotte, Taking charge: Manufacturers Support Growth with Active Workforce Strategies

Traditional recruitment methods often fail to meet the expectations of younger generations, who tend to prioritize technology-driven, efficient, and engaging work environments. The implementation of advanced technologies such as MES can address this challenge by increasing operational efficiency and supporting the development of a modern workforce.

MES not only streamlines manufacturing processes but also can act as a recruitment and retention tool, appealing to workers who value high-tech environments and helping them develop the skills they need to meet evolving demands. MES fosters workforce engagement by creating a more organized and transparent work environment, improving job satisfaction and retention rates.

  • Simplified job scheduling gives workers greater visibility into their tasks, reducing confusion and improving productivity.
  • Real-time productivity tracking allows employees to monitor their own progress, fostering a sense of accomplishment.
  • Intuitive interfaces make it easy for employees to adapt to new processes, enhancing both efficiency and job satisfaction.
  • Machine monitoring and instant alerts enhance employee safety, making smart facilities workplaces of choice for today’s manufacturing employees.

Build a Stronger Workforce with SYSCON PlantStar

SYSCON PlantStar offers a range of MES solutions tailored to the needs of modern manufacturers. From intuitive interfaces to advanced real-time monitoring capabilities, PlantStar’s MES systems empower manufacturers to overcome workforce challenges and achieve operational excellence. Because the successful adoption of MES systems requires robust training and ongoing support, SYSCON PlantStar provides training and support services that ensure your employees will be able to confidently leverage the full capabilities of the system, driving both individual and organizational success.

Investing in MES goes beyond simply improving operational efficiency; it empowers your workforce to thrive amid constant change in the manufacturing environment. By bridging the skills gap, supporting lean practices, and fostering workforce engagement, MES systems play a critical role in building a resilient and adaptable manufacturing workforce.