Data is not just an asset—it’s the backbone of operational excellence. Yet despite the vast amount of data flowing through organizations, many still struggle to unlock its full potential. The reason? Disconnected systems and data silos that prevent organizations from viewing the complete picture. Webalo transforms isolated data into unified insights that empower organizations to optimize processes, improve performance, and foster continuous improvement.
Bridging the Gap Between IT, OT, and Workforce Data
A key challenge many manufacturers face is the disconnect between OT, IT, and workforce data. OT systems, like SCADA and MES, provide real-time operational metrics from machines. IT systems, such as ERP and WMS, support strategic planning by handling business and operational data. Yet, both systems overlook a crucial piece: knowledge data—the insights generated from workforce actions, feedback, and execution.
Webalo’s Platform connects these disparate sources of information, enabling organizations to integrate human and machine data. By consolidating operational data with workforce insights, Webalo provides a unified view of production dynamics, helping manufacturers identify patterns, optimize workflows, and drive real-time improvements.
The Power of Combining Human and Machine Data
Webalo’s Platform offers seamless integration of human and machine data to deliver holistic insights such as:
- Combined Human and Machine Data: This integration allows organizations to identify inefficiencies, reduce downtime, and improve workflows by combining operational and workforce data.
- Real-Time Dashboards for Leadership: With Webalo, leaders can access actionable insights through real-time dashboards, enabling informed decision-making and improved standardization across the organization.
- Embedded Workforce Feedback: Webalo captures frontline observations, turning them into actionable data that enhances analytics and creates feedback loops for ongoing optimization.
Real-World Applications: A Unified Approach to Efficiency
Manufacturers using Webalo can dramatically reduce inefficiencies, standardize best practices, and fuel operational transformation. For instance, integrating machine maintenance data with worker feedback helps companies pinpoint recurring issues, implement preventative measures, and reduce downtime by up to 30% annually.
By providing leaders with real-time insights into efficiency and bottlenecks across multiple sites, Webalo empowers organizations to make data-driven decisions, drive consistency, and optimize operations at scale.
Addressing the Data Utilization Gap
Despite the abundance of data generated by IT and OT systems, manufacturers often underutilize this information. A single production line can produce more than 400,000 daily data points from OT systems like SCADA and MES. IT systems contribute additional layers of data. Yet, Gartner reports that less than 30% of this data is effectively analyzed.
The main challenges manufacturers face in making the most of their data include:
- Disconnected Systems: While IT data supports strategic decisions, and OT data monitors machines, neither system captures the critical human context—the "why" behind inefficiencies or anomalies.
- Lack of Human Context: Machine metrics only show “what’s happening” but fail to explain “why” things are happening, leaving manufacturers unable to understand the role human behavior plays in performance.
- Missed Optimization Opportunities: High-level reports from IT systems often overlook granular, real-time issues on the shop floor that need immediate attention.
Knowledge Data: The Missing Link
What’s often missing from the data equation is knowledge data—the insights generated from how workers interact with equipment, handle tasks, and respond to challenges. Knowledge data includes elements like:
- Task completion rates and worker feedback
- Observations about anomalies or operational inefficiencies
- Human decisions made in response to equipment behavior
When integrated with IT and OT systems, knowledge data provides the missing human context to the machine data, allowing manufacturers to achieve a holistic view of their operations.
The Benefits of Integrating Knowledge Data
By integrating workforce insights with machine and business system data, Webalo offers several key benefits:
- Deeper Analytics: Understand the root causes of inefficiencies and downtime by uncovering the interplay between human actions and machine performance.
- Predictive Insights: Forecast potential issues more accurately, leading to proactive decision-making and optimized workflows.
- Standardization: Identify best practices across sites, helping organizations standardize processes and continuously improve performance.
Achieving Manufacturing Excellence with Webalo
Webalo’s Connected Worker Platform is more than just a data integration tool—it’s a transformative solution that enables manufacturers to move beyond simply understanding what is happening to uncover why it’s happening. By connecting human insights with machine and IT data, Webalo empowers manufacturers to make smarter decisions, streamline operations, and ultimately achieve manufacturing excellence.
With Webalo, organizations no longer need to navigate the complexities of disconnected systems or rely on incomplete data. Instead, they can leverage the full power of their data—transforming it into a strategic asset that drives operational excellence and continuous improvement at every level of the business.
