There is often a gap between the theory of procedures and their actual application in the field. How can we deal with this effectively?
In industrial environments such as factories or logistics warehouses, there is often a gap between the theory of procedures and their actual implementation in the field. Best practices defined on paper are often difficult to follow in a dynamic environment, where unforeseen events, material and human constraints, and the complexity of operations make perfect execution almost impossible. Digitizing processes is a powerful lever for reducing this gap.
Several factors explain why the procedures and standards designed upstream are not always respected in the field:
- Lack of training and updating of skills: Operators and logistics staff may not have a clear or up-to-date understanding of procedures.
- Mismatch between planning and reality: Working conditions vary constantly, and procedural documents do not always take these fluctuations into account.
- Communication difficulties : Poor transmission of information between hierarchical levels slows down the implementation of best practices.
- Lack of real-time feedback : Without clear and accessible indicators, it is difficult for operators to measure their compliance with standards.
Digital transformation aligns theory and practice by making procedures more accessible, measurable and adaptable in real time. Here are the main levers of digitalization:
Paper procedures are often tedious to consult and can quickly become obsolete. A digital system allows you to :
- Instantly update work instructions.
- Make procedures interactive via mobile and tablet applications.
- Use visual formats (videos, infographics) that are more effective than traditional manuals.
Technologies such as augmented reality (AR) and interactive tablet guides enable operators to train continuously without interrupting production. For example:
- Interactive tutorials integrated into equipment.
- Voice assistants to guide operations in real time.
- Micro-learning platforms accessible in the field.
IoT (Internet of Things) tools and sensors make it possible to monitor performance live and alert to deviations from procedures. For example:
- A digital dashboard that displays KPIs in real time.
- Automatic alerts in the event of non-compliance with safety instructions.
- Monitoring of movements and postures to reduce the risk of MSDs (musculoskeletal disorders).
Some human errors can be eliminated by automating procedures:
- Use of RFID scanners to track goods flows without manual intervention.
- Collaborative robots (cobots) to assist operators with repetitive tasks.
- Digital checklists to verify compliance with procedures before validation.
Collaborative tools such as mobile applications and cloud platforms enable teams to :
- Share updates and feedback instantly.
- Reduce the waiting time between problem reporting and resolution.
- Encourage continuous improvement through feedback loops.
Let's take the example of a logistics warehouse that has implemented a digital work instruction and training system. Before digitization, order-picking errors were frequent, and safety instructions were rarely followed to the letter.
After digitization:
- Installation of mobile terminals: Operators receive the latest instructions.
- Guidance by video tutorials: Clear videos show the optimal route through the warehouse.
- Automatic feedback: A form system allows validation of each step or the reporting of a problem in real time.
The result: a 30% reduction in errors and a significant improvement in productivity.
Reducing the gap between theory and practice in an industrial environment relies on better information transmission and real-time monitoring. Digitizing processes, by making instructions more accessible, performance more measurable and tasks more automated, helps minimize discrepancies and optimize operational efficiency.
For a successful transition, it is essential to involve operators from the outset of the project, to offer simple, intuitive tools, and to provide ongoing support for optimal adoption of these new technologies.
"With Komin, we have documented our operating procedures 10x faster than with paper"
- J. Cerruti (Methods & Industrialization Manager)
