Connected worker
Connected worker software: instructions, skills and training at the line
A connected worker platform gives operators and technicians the right instruction, at the right step, on a tablet or phone at the machine, and records who did what and whether they were qualified to do it. It combines digital work instructions and video SOPs, a skills matrix, training and certification records, and links to MES, quality and maintenance.
Free scoping call. We start with one line, never change your machine logic, and you own the code and the data.
- material movements tracked a day, integrated steel plant
- 720,000+
- fewer dispatch errors with RFID and barcode dispatch
- 90%
- items an hour through RFID warehouse automation
- 16,800
Company reported project figures, not independently audited, not a promise for another plant. Samsung Business Insights: our RFID warehouse automation story (opens in a new tab). Forbes India Brand Connect (sponsored): founder profile (opens in a new tab).
Sound familiar?
- Work instructions are laminated sheets that are three revisions out of date.
- Training a new operator depends on who happens to be on shift.
- An auditor asks who was trained on the current revision, and the answer is a search.
- A critical step was done by someone not certified for it.
Each of these is output, margin or time you have already paid for and are not getting back.
What you get
One process digitised
Step by step instructions with photos and short videos, written with the people who do the work.
Skills and sign off
Who may do the step, and a record that they did.
QR at the machine
Scan to open the right procedure for that asset.
Before and after
Training time, errors and audit findings, measured.
What we have built
Our QR based maintenance and video SOP systems support blast furnaces, coke ovens, rolling mills and processing lines, with more than ₹80,000 crore (about US$9.6 billion) of machinery under maintenance.
Figures are company reported from past projects. They are not independently audited benchmarks and are not a promise for another plant. Read the case studies.
How we work
What we build
We build connected worker tools as part of an MES or as a standalone system: digital instructions and QR video SOPs at the machine, skills and training records, and integration with your MES, ERP, quality and maintenance systems. Our digital SOP and gamified learning systems are in use in large Indian manufacturing groups.
How we start
- 1Pick one process. A station or maintenance task with frequent errors or long training time.
- 2Digitize the instruction. With the people who do the work, including photos and short videos.
- 3Add skills and sign off. Who may do the step, and the record that they did.
- 4Measure and extend. Training time, errors and audit findings before and after.
How it works
Where it pays back
- High mix assembly where instructions change often.
- Plants with high turnover or many temporary and contract workers.
- Maintenance tasks on complex assets that are done rarely.
- Regulated work where training and sign off records must be shown to auditors.
What to check before choosing
- Can supervisors and engineers update instructions without IT?
- Does it work offline or on poor plant WiFi?
- Does it support the languages your workforce reads?
- Can it read work orders from your MES or ERP and write results back?
- Does the skills matrix block assignment, or only report after the fact?
Background
What a connected worker platform covers
| Function | What it does |
|---|---|
| Digital work instructions | Step by step instructions with photos, video and checks, tied to the product and revision |
| Video SOPs by QR code | Scan a code on the machine to open the procedure for that asset |
| Skills matrix | Who is trained and certified on which operation, with expiry dates |
| Training and certification | Assign, deliver and record training, including refreshers when an instruction changes |
| Data capture | Checks, measurements and sign offs recorded at each step |
| Integration | Work orders from MES, defects to quality, requests to maintenance |
When we are not the right choice
- You need a full learning management system for office staff. An LMS product fits better.
- Instructions rarely change and staff turnover is low.
Common concerns, answered
Will this disrupt production?
No. We connect read only first, install during planned stops, and edge devices buffer data so a network problem never stops a machine. Nothing writes to a PLC without your controls team and a test.
Our machines are old. Do we need to replace them?
No. Old machines are the usual case. A running signal, a cycle signal or a current sensor on the motor is enough to start, without touching the machine program.
We tried a system before and nobody used it.
That is the most common failure, so we design with the operators and supervisors who will use it, start with one report they already fill in by hand, and only extend once they rely on it.
What about IT security?
Read only by default, a segmented OT network, and a review with your IT team before anything connects, following the ISA/IEC 62443 zone approach.
We will not replace SAP or Oracle. Do we have to?
No. We connect to the ERP you already run through its standard interfaces and add what the shop floor is missing. Your ERP stays the system of record.
Do your engineers understand a heavy industrial floor?
Our systems run in steel plants, warehouses and process lines. We start every project by walking the line with your operators and supervisors, and the first release is tested by them, not only by IT.
Are we locked in?
No. You own the source code and the data, documented, in your own repository. Another team can maintain it.
Frequently asked questions
What is a connected worker?
A frontline worker who uses digital tools, usually a tablet, phone or wearable, to receive instructions, record work and communicate, with that data connected to plant systems.
Is connected worker software the same as MES?
No. It focuses on people: instructions, skills and training. An MES manages orders, materials, machines and genealogy. They work best connected.
Can it manage a skills matrix and certifications?
Yes. Skills, certifications and expiry dates per person and operation, with alerts before expiry and checks at assignment.
Does it replace our HR or payroll system?
No. It records operational skills and training. HR, time and attendance and payroll stay in your HR systems, and can be linked.
Related reading
References
Start with one line and one number
We scope one line, agree the number that should move, and show it moving before anything is scaled. You keep the code and the data.
Step 1
An engineer reads it
Not a sales bot. Our team replies within 24 hours with questions or times for a call.
Step 2
30 minute call
Your process, machines, systems and the number you want to move. We tell you honestly if we are a fit.
Step 3
A written scope for one line
What we would connect, what you would see, how long it takes. You decide; nothing starts without your approval.
Reviewed by Amey Kadle, Founder, Ajinkya Technologies. Last reviewed: .