AI in manufacturing: Balancing innovation and workforce readiness

AI. It’s the shiny new thing in every industry, and manufacturing is no exception. Whether it's streamlining operations, boosting efficiency, or making workplaces safer, AI promises to shake things up in big ways.

But here’s the catch: it’s not just about fancy algorithms or automating tasks. The real challenge? Bringing AI into the company in ways that make manufacturing safer, help address workforce shortages and give people already in the workforce a career boost.

We had the opportunity to headline a discussion on this very topic at the Manufacturing Institute’s Workforce Summit earlier this month. Our panel, “Technology, Organization, and Leadership: AI’s Influence on Manufacturing’s Future” was a wide-ranging discussion about where most companies are applying AI today. We also explored the ways each of us can leverage AI tools inside and outside the workforce, and maybe most importantly that it’s not “the AI”.

AI: A game-changer for safety

AI is shifting how we think about safety, far beyond just physical robots on the factory floor. Imagine AI-powered systems that help workers avoid accidents by interpreting patterns and trends in massive amounts of data. For example, AI can guide a new employee through troubleshooting complex equipment by referencing years of performance data and manuals, making the process faster and safer.

AI could identify if an operator requires more training based on their handling of certain machines, or pinpoint locations within the plant where incidents tend to spike when specific equipment is used. The result? A proactive approach to safety that empowers workers with real-time insights and keeps potential hazards at bay. This isn't just about taking on dangerous tasks but creating an environment where AI and workers collaborate to reduce risks through better data and smarter decisions. In the end, fewer injuries, improved performance, and a workforce that can focus on developing skills instead of dodging risks.

But here’s the kicker: it’s not enough to simply throw AI into the mix. The trick is to find and implement the use cases that solve problems for the workers – real problems like injuries or down time. These tools and the insights they produce are ways to help people grow their skills and their expertise, at a faster pace than before.

The employee dilemma: Enthusiasm meets hesitation

Now, let’s be honest — AI isn’t being met with cheers from everyone on the shop floor. Sure, executives are all-in, excited about the operational efficiency and speed to market that AI hype machines promise. But employees? It’s complicated. Some are excited, especially the crowd that’s grown up with AI-powered apps and gadgets. For them, AI’s one more cool technology that makes life easier. But for others, especially those who’ve been around a while, AI can feel threatening.

But the truth is that AI needs people. Rolling out AI isn’t as easy as installing tech and walking away. There’s a wealth of knowledge in the hands of experienced workers that, if left untapped, could be lost as they retire. AI can help retain that expertise, transforming years of hands-on experience into a training resource for new employees. Imagine an AI system that analyzes the workflow of seasoned operators and makes that knowledge easily accessible, training new staff through real-time, data-backed insights. This doesn’t just ensure continuity but helps build a solid foundation of knowledge for future generations of workers.

By embedding AI into the company’s knowledge management, you retain critical know-how while speeding up the training process for new hires. AI tools can store, organize, and present this data in ways that are accessible anytime, making it a pivotal part of employee development.

AI and career growth: Paving new paths

Let’s shift gears for a minute. One of the least discussed aspects of AI is the opportunities it creates for career growth. In manufacturing, a lot of workers start in entry-level roles, often stuck on the worst shifts. But AI can change that. By using AI-powered tools for training and career development, companies can help employees move up the ladder — literally and figuratively.

Picture this: an entry-level worker starts out operating machines during the night shift. Over time, they use AI-driven learning platforms to gain new skills and gradually shift to higher-paying, day-shift roles. AI could even help map out personalized career paths for employees, showing them which skills they need to develop to move up. And it can power the training that person needs – whether it’s delivered via augmented or virtual reality or through self-paced self-study.

For manufacturers, this is human resources gold. Not only do they retain talent, but they also keep their workforce engaged and motivated. And when employees see that they’re moving forward in their careers, the dreaded “I’m little more than a cog in the machine” feeling disappears. The employers get happier, more sticky employees. And the employees get engaged in a career path they helped craft.

Change management: It’s all about the people

Let’s not kid ourselves — change isn’t easy, especially when it involves new technology. Drop AI into a factory and expect everything to magically work? That’s not going to happen. Let’s make this point loud and clear: the success of AI depends on how it’s rolled out. It’s not enough to invest in fancy tech if your people don’t know how to use it or, worse, don’t even want to.

So, it’s no surprise that AI adoption rates are often sluggish when companies ignore this critical human element. Workers need the right guidance, encouragement, and an environment where they feel safe experimenting. Without this, AI will remain an unused tool, or worse, a misused one. Companies that focus on clear, ongoing change management will avoid frustration and foster a workforce ready to make AI part of their everyday toolkit.

Here’s the reality check: if leaders don’t prioritize change management, they’ll end up with frustrated employees who either won’t use the tools or, worse, will use them incorrectly. And that’s a recipe for poor return on investment.

The human side of AI: Making it work for everyone

Where does this leave us? AI is here to stay, and it’s going to keep changing the manufacturing world. But if manufacturers want to make the most of it, they need to focus on more than just the bottom line. The future of AI in manufacturing isn’t just about smarter machines — it’s about smarter and safer workplaces, where technology and people work together to make humans even more capable than they were before.

The manufacturers who get the balance between innovation and workforce readiness right will be the ones who not only survive the AI revolution but thrive in it. They’ll be the ones who use AI not only to cut costs but also to create a more engaged, motivated workforce. AI can help you do things faster or cheaper. But more importantly, it can help you do things better — for the business, for the workers and for the future of the industry.

Master your GenAI destiny.