Smart Automation Certifications Help Alleviate the Manufacturing Skills Gap
65. The magic number – retirement. The day many dream of, and by 2030 all Baby Boomers will have reached this age. While many will be celebrating, the manufacturing and skilled‑trades sectors are facing a long‑anticipated workforce shift that’s now accelerating. These jobs aren’t being filled, and long-standing employees are retiring without passing down their institutional knowledge.
As experienced workers retire and technology advances, the gap between what employers need and what incoming workers can do is widening faster than traditional training can keep up. That’s why the industry needs a more consistent, reliable way to define, teach, and validate the competencies required in today’s production environments. Industry‑recognized certifications like the Smart Automation Certification Alliance (SACA) offers exactly that.
In a workforce that’s evolving this quickly, a shared approach to identifying and validating skills becomes a practical way to narrow the widening gap.
What’s Widening the Skills Gap
As these Baby Boomers retire, they take decades of hands‑on knowledge that isn’t easily replaced by manuals or classroom instruction. These workers learned through experience, troubleshooting problems that newer employees may never have encountered. When they walk out the door, that expertise goes with them, leaving companies scrambling to capture what they can before it’s gone.
While retirement is the most visible contributor, it’s only one piece of a much larger challenge reshaping the workforce. Technology is also evolving at an exponential. Advanced automation, robotics, smart sensors, and data‑driven systems are now standard across production environments. Research also shows that 85% of jobs that will exist in 2030 have not yet been invented.
The result is a widening disconnect between what modern equipment requires and what the average worker has been prepared to do. Manufacturers aren’t just looking for operators anymore, they need technicians who can interpret data, diagnose complex issues, and keep interconnected systems running with minimal downtime.
The challenges for manufacturers are clear. And they aren’t going to resolve themselves. What the industry needs now is a workforce development model built for the realities of modern manufacturing. One that keeps pace with technology, captures critical knowledge before it disappears, and gives both new and existing workers a practical path to build the skills employers need.
SACA and the Skills Gap
Manufacturers need training that’s aligned, consistent, and built around the actual competencies required on today’s smart, connected production floors. That’s precisely why the Smart Automation Certification Alliance (SACA) has become so important. Designed by industry, for industry, SACA certifications are built to validate the capabilities workers need to succeed in advanced manufacturing environments. And as more employers and schools adopt these standards, the industry is beginning to see what a unified approach to workforce development can really accomplish.
Hiring for manufacturing operations roles is difficult, and HR managers often have to rely on blind trust when an applicant says they can troubleshoot a sensor network or interpret machine data. With SACA certifications, the candidate can prove they’ve showcased their ability to perform those skills by an unbiased third party. That standardization removes a tremendous amount of uncertainty from hiring, onboarding, and upskilling.
But SACA’s benefits go beyond consistency. The certifications are designed to be fast, flexible, and aligned with the pace of modern technology. Workers can build skills in stackable increments, earning credentials that reflect specific competencies rather than broad, outdated job titles. This modular approach makes it easier for employers to target training where it’s needed most and for employees to advance without stepping away from the workforce.
CTE programs are taking that same fast, flexible approach and applying it to the next generation of manufacturing talent. By integrating SACA’s stackable credentials directly into their coursework, schools can teach skills in focused, competency‑based segments that align with what employers actually need on the plant floor. Instead of broad survey classes that may or may not translate to real‑world roles, students build practical abilities step by step.
Building a Faster, More Reliable Talent Pipeline
Taken together, these shifts show just how urgently manufacturing needs a new approach. With industry and education aligned around the same standards, the path forward becomes clearer and far more achievable. And as more manufacturers adopt tools like SACA to strengthen both their talent pipeline and their existing teams, the industry moves closer to a future where workforce shortages no longer hold back innovation or growth.
When everyone is working from the same understanding of what “job‑ready” truly means, hiring becomes more efficient, training becomes more targeted, and workers gain a clearer path toward meaningful careers. The result is a talent pipeline that’s not only stronger, but also more adaptable to the rapid changes shaping modern work.
Are you interested in utilizing SACA certifications for your own company’s training? Learn more about Industry Memberships here.
Are you a school looking at preparing your students for a career in Industry 4.0? Learn more about Education Memberships here.
Want to learn more about the best use cases of SACA certifications across the country? Join us at the SACA National Conference August 10-11, 2026 in Menomonie, WI.
Industry Credentials Turned a Career’s Worth of Experience Into College Credit
SACA certifications give learners a way to turn real-world expertise into college credit, saving time, reducing costs, and accelerating career growth.
For any parent, their child’s graduation is a moment of pride. For Jason Solberg, it’s also a personal milestone. This spring, he’ll don his cap and gown alongside his son, Tyler, as both become some of the first graduates of the University of Wisconsin-Stout’s new Bachelor of Automation Leadership program.
The degree is the first of its kind, offering students an opportunity to blend technical skills with industrial business leadership expertise. The program prepares learners to lead in areas such as Industry 4.0, digital transformation, and operations management.
What makes this program so unique is that 61 credits can be transferred through associated credentials from the Smart Automation Certification Alliance (SACA), a national certification body that delivers industry-recognized certifications and microcredentials in advanced manufacturing and Industry 4.0. SACA silver certifications are written exams that test knowledge, and gold certifications are hands-on assessments that measure technical skill.
Add general education credits, and students can transfer up to 88 total credits to UW-Stout from any technical or community college in the country that has a transfer agreement with UW-Stout.
In other words, students can complete 75% of a 120-credit bachelor’s degree without paying university tuition.
To finish their degree, students will build on their technical foundation with courses in IoT, lean manufacturing, project management, and digital strategy. Then, they’ll complete an automation leadership internship and final capstone project. These capstones showcase a student’s understanding of both the technical and business sides of a project, including scheduling, budgeting, team management, and communication.
Jason Solberg describes himself as a man who’s done a little bit of everything, with a career that has spanned roles, technologies, and learning environments. That versatility is exactly what accelerated his journey through the Automation Leadership degree.
Jason’s has had roles in operations, maintenance, automation, and instruction, with roles at Tecumseh Products, Waukesha Engines, and GE. Early on, he pursued technical education at Moraine Park Technical College and completed a journeyman apprenticeship at Waukesha County Technical College (WCTC).
Having spent over two decades in industry, Jason moved to the world of education after discovering a job listing for an adjunct instructor position at WCTC. “I took the plunge and I went to the other side and became a teacher. It was terrifying because I never taught a day in my life.”
After nine years of teaching, Jason has now taught over 28 different courses and set up five apprenticeship programs. “I don’t teach for the money. I do it because I want to make a difference in people’s life.”
Always looking to grow, Jason had recently enrolled at Lakeland College for data analytics when WCTC Associate Vice Provost of Academic Affairs, Mike Shiels, mentioned a new program that might be of interest. The University of Wisconsin-Stout’s new bachelor of Automation Leadership was being rolled out and looking for students. With the SACA credential portion of the degree, Shiels explained how Jason could gain credit for his years of experience.
“I just took whatever [SACA assessments] just to see, test myself. I got 15 or 16 silvers from that,” Jason explains how he received his SACA credentials. He then spent 4 days at Lakeshore College in Cleveland, Wisconsin testing for his gold certifications. “I didn’t even study. I went in there and I walked away with 10 golds.” These credentials will translate into 28 credits towards Jason’s degree.
Unlike the traditional credit for prior learning model, which maps to courses, Stout’s model uses the earned SACA credentials to award credit. According to Program Director Dr. Xuedong (David) Ding, “SACA makes this program possible. Because if there is no national or internationally-recognized skill set competencies certificate, this program would not be available.”
Dr. Ding also explains how SACA’s industry-validated and standardized benchmarks, along with flexible delivery, enabled the University to format the program to support reshoring American manufacturing.
Jason is the perfect example of what makes the Automation Leadership degree so unique. By earning his 25 SACA certifications, he validated decades of hands-on experience and turned those credentials directly into college credit. This allowed him to reduce the time it will take to obtain the degree as well as reduce tuition costs, since converting certifications into credits meant fewer classes to pay for. Jason’s journey shows that when education aligns with experience, learners can move forward faster, with greater purpose and impact.
“I like to lead by example, and I want to pave the path for our apprentices because I’m an apprentice,” Jason shares.
Now that Jason has taken his own certifications and knows the variety of credentials SACA provides, he uses them as a planning tool to shape his courses at WCTC. SACA helps him align labs, lectures, and assessments with the exact skills students will need in the field. This approach gives students a clear path toward earning certifications while they learn, and it ensures that every lesson connects directly to real-world outcomes.
And because WCTC has a transfer agreement with UW-Stout, Jason’s students also have a clear pathway to an Automation Leadership degree if they want to continue their education.
Tyler Solberg, Jason’s son, had also started the Automation Leadership program at the same time as Jason and was able to transfer 19 credits into the program from his dual enrollment at Oconomowoc High School.
For his capstone project, Jason worked with Tyler and another classmate, Wesley Lidwin, to complete a multi-year project to develop a coil winding training station for Eaton. Jason often conducts training bootcamps for Eaton employees, and Eaton offered $350,000 to fund Jason’s leadership of the new training program.
[A look at the coil training line at Eaton coordinated by Jason and his team.]
Dr. Ding oversees Jason’s capstone project and predicts the training Jason coordinated will have a continued impact on Eaton beyond this first project. “[The coil training line] impacted the whole culture of that facility. It transferred from a semi-automated or manual operation to a fully automated production. So, they have a more competitive edge compared to competitors nationally and internationally.”
Jason and Tyler’s journeys show how SACA certifications create real opportunities for learners at every stage, from high school students just starting out to seasoned professionals with years of experience. While Tyler used dual-enrollment credits to begin his degree early, Jason converted decades of hands-on expertise into college credit through performance-based certifications. Each took a different path, but both will end up in the same destination as they walk the graduation stage together this spring.
Whether students are just starting out or bringing years of experience to the table, SACA helps them build meaningful skills that connect directly to the workplace. It turns learning into progress, and progress into possibility.
Learn more about Jason’s capstone project here.
Find the current offerings of SACA certifications here.
Learn more about the Automation Leadership degree here.
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SACA Welcomes New Executive Program Director
The Smart Automation Certification Alliance (SACA) is pleased to welcome Sue G. Smith as its new Executive Program Director. Smith joined SACA in May 2024 after working at the highest levels within Indiana’s Ivy Tech Community College for more than 30 years.
During her tenure with Ivy Tech, Smith developed expertise in consulting; workforce and economic development; program and partnership development; and advanced and smart manufacturing. Most recently, she served as Vice President of Ivy Tech’s award-winning School of Advanced Manufacturing, Engineering, and Applied Science (AMEAS).
At Ivy Tech, Smith prioritized strengthening programs with an eye toward economic and workforce development. In particular, she worked extensively with employers throughout Indiana and neighboring states to ensure the programs in the School of AMEAS aligned with industry needs.
Under Smith’s leadership, Ivy Tech’s School of AMEAS grew to be a major economic development resource for Indiana. It also became the first college in the United States to develop and deliver a smart manufacturing degree called Smart Manufacturing Digital Integration (SMDI).
Ivy Tech’s SMDI degree was based upon SACA credentials that were vetted with manufacturing employers. The SMDI degree has been especially attractive to new industries looking to move into Indiana, since advanced automation skills are critical for cutting-edge technologies used in electric battery, electric vehicle (EV), semiconductor, and biopharmaceutical manufacturing.
The success of Ivy Tech’s School of AMEAS and its groundbreaking SMDI degree has captured the attention of not only other community colleges and universities around the country, but also organizations around the world. In fact, Smith recently delivered a keynote address at the European Educational Congress in San Sebastian, Spain, on smart manufacturing and the implementation of embedding SACA credentials stacking into programs.
SACA Executive Director Jim Wall is excited to see Smith use her experiences at Ivy Tech to help other organizations build similar programs. According to Wall, “SACA’s been growing pretty dramatically in the last two years, so we needed to bring in a nationally-known leader in education and industry. We’re very proud and fortunate to say that Sue Smith has come on board as our Executive Program Director.”
Wall notes that “Sue’s primary responsibility is going to be helping to grow SACA membership by being a resource for instructors and administrators across the country. She’ll also be working with some of our industry partners to help them develop pathways internally for their employees that can utilize SACA certifications.”
Smith says, “I’m really excited to be with SACA.” Reflecting on her journey from Ivy Tech to SACA, Smith notes that “as I rolled that [SMDI] out at Ivy Tech, I got tons of calls from other community colleges and organizations saying, ‘Hey, how did you do this? Can you do this for us?’ So, when this position came up, I thought, ‘Yeah, I think I can do that for other schools and other industries.’”
What does Smith hope to accomplish with SACA? “I’m trying to accomplish that sort of ‘high tide raises all boats,’ if you will. I’m trying to make this opportunity available for employers and for community colleges and universities in any state.”
About SACA
SACA sits at the forefront of the effort to certify students and workers who demonstrate the required knowledge and hands-on smart automation skills employers so desperately need. SACA’s certifications were developed in conjunction with industry partners who could speak from experience about their needs when it comes to workers able to work alongside a variety of advanced automation technologies.
SACA offers a wide variety of certifications in popular industrial skill areas, including certifications at the Associate, Specialist, and Professional level. For those wishing to focus on building a strong foundation of skills employers need, SACA also offers many micro-credentials that allow students and workers to add certifications as they master new areas.
For workers, SACA certifications can help market their smart automation skills to potential employers. For those employers, SACA certifications represent confirmation that a worker has the skills to hit the ground running in the workplace. To learn more about Industry 4.0 certifications and how SACA can help both future workers and industrial employers begin the task of bridging the Industry 4.0 skills gap, contact SACA for more information.
- Published in News
Identifying specialists within the Industrial Internet of Things (IIoT).
Supply chain issues persist within the global manufacturing industry. Although nimble companies have found ways to navigate the issues brought about by COVID19, experts still anticipate concerns continuing through 2022, caused by the lingering effects of the pandemic and other global events.
One of the most pervasive issues stems from the reality that domestic manufacturing relies heavily on components made in other countries. While efforts are being made to mend this, in particular attempts to re-instate the component manufacturing industry in the US, it’s clear that this industry will reemerge in a different way with a focus on mechanization and automation.
The foundation of a long term strategy to mitigate these problems in the future will involve leveraging the Industrial Internet of Things (IIoT), which presents a groundbreaking opportunity for data capture at each step of a manufacturing process.
This extensive study by Inmarsat indicates that many manufacturing companies are either already using or anticipate using IIoT to enhance their productivity. A smart factory can track all elements of the production chain and communicate information and even anticipations within the network.
In addition to valuably capturing data, a smart-automation chain can perform pre-emptive actions based on the needs of the incoming workload; for example submitting a work-order for components required on the production line, utilizing a company’s secure industrial WLAN.
Unlike residential (or office) WiFi, an industrial system transfers small amounts of data, and as such requires a small amount of power but must remain uninterrupted. Knowledge of the specificities of these systems is essential to optimize an efficient order-to-customer pipeline.
Because of innovations like re-programmable robots and even rent-a-bot companies emerging, there is much less danger of expensive built-in obsolescence and more opportunity for network, automation and programming specialists within manufacturing companies.
Companies searching for highly-skilled workers to ease their supply chain disruptions want to make sure that potential employees actually have the skills to excel without significant additional training. That’s why industry-standard certifications are important for supply chain workers. They provide employers with evidence that a worker has the knowledge and hands-on skills to work with today’s advanced technologies.
Industrytoday.com states that ‘new developments in automation are allowing small manufacturers to meet demand while helping with American competitiveness’. Today’s workers need more advanced technical and technological skills than ever before. Unfortunately, there aren’t enough workers with these skills to fill the many roles available today, creating what is known throughout industry as the “skills gap.” Modern businesses must ensure that their workers have up-to-date, relevant accredited skills. How can companies be sure that their employees are at the correct skill-level?
The Smart Automation Certification Alliance (SACA) focuses on connected-systems skills and leads the effort to certify students and workers who demonstrate the required knowledge and hands-on smart automation skills employers so desperately need. SACA professional development opportunities provide extensive training courses to equip teachers to promote Industry 4.0 certifications. These professional development opportunities are offered throughout the year at regional centers. Courses last 3-5 days each. Upon successful completion of each course, teachers will be certified in the process of examining students for a given credential and administrating a certification preparation course.
To learn more about Industry 4.0 certifications and how SACA can help both educational institutions and industry employers begin the task of bridging the Industry 4.0 skills gap, contact SACA for more information.
Header Photo by Denny Müller on Unsplash
- Published in News
SACA Certifications: Industry’s Missing Link to Solve the Skills Gap
It’s no secret that industries of all kinds are battling a serious supply and demand issue. Due to advancing technology and increasing use of automation, employers need more highly-skilled workers than ever before.
Unfortunately, the supply of workers with the advanced technical and technological skills employers need isn’t keeping pace. This well-known problem is known as the “skills gap.” It’s been a problem for a while now, and experts believe it will only get worse in the near future.
What employers need are workers with advanced “connected systems” skills that will help them operate, maintain, troubleshoot, and repair the automation equipment becoming commonplace in facilities that have adopted new Industry 4.0 technologies.
To date, however, industry and educators alike have been missing the key to solve this skills gap: a set of industry-defined and industry-validated standards that clearly define the skills workers will need to succeed in the jobs of the present and future.
Providing that missing link was the guiding vision behind the creation of the Smart Automation Certification Alliance (SACA). In a recent webinar (“SACA Webinar”) hosted by Matt Kirchner, President of Lab Midwest, representatives of several major manufacturers spoke about their role in the development of SACA’s Industry 4.0 skill standards, as well as how those standards are now guiding their training and education efforts.
SACA’s Vision for Industry 4.0 Certifications
Why are SACA’s Industry 4.0 certifications so valuable? They speak to the in-demand skills that employers across the country — and across the globe — need so desperately.
Not only do the nation’s educational institutions need to build a pipeline of skilled talent to supply employers with the highly-skilled workers they need now and in the future, but incumbent workers also need training to learn the new skills they need to work with the advanced Industry 4.0 automation systems taking over modern manufacturing facilities.
But what are those skills? That’s the key question, and answering that question is what brought SACA into existence. According to SACA’s Executive Director, Jim Wall:
“SACA’s vision from the beginning was to develop a system that’s based upon industry-developed, industry-validated standards that truly define the competencies, performance indicators, and knowledge indicators that are required of individuals to succeed in the world of Industry 4.0.”
To turn that vision into reality, SACA relied upon a wide variety of companies, educational institutions, and organizations to develop, review, and test SACA certification standards. Experts from well-known industry leaders, such as Rockwell Automation, FANUC, Ashley Furniture, Kohler, Foxconn, Boeing, and Hershey, were instrumental in making sure SACA’s Industry 4.0 certifications reflect the competencies that industry needs.
Industry 4.0 is Here to Stay
Several of the industry representatives who shared stories during the SACA Webinar spoke about the changes that Industry 4.0 technologies have wrought and how their companies have been forced to respond.
Al Doty, Advanced Manufacturing Chief Engineer for Harley-Davidson, Inc., revealed that automation has been key to his company maintaining a competitive edge. Not only do new technologies improve efficiency and reduce costs, but Doty noted that employees also expect the company to adopt and use the best technologies available, so that they can perform their jobs more effectively and maintain a positive work-life balance.
Specific new technologies being adopted include advanced robotics and digital twins, according to Scott Theune, President of Plexus. Digital twins are realtime digital counterparts that allow workers to troubleshoot equipment virtually.
In addition to improving efficiency, these new technologies also play a critical role in making manufacturing facilities safer. Improved safety has been a big benefit as industry growth and the skills gap has spurred the need for more automation, noted Andrew Martin, Senior Director of Manufacturing for Generac.
Leaders throughout industry agree: Industry 4.0 is here to stay. According to Michael DeBroux, Senior Mechanical & Automation Engineer and Engineering Supervisor of Greenheck Fan Corporation, “We need to make sure that we are getting personnel and new talent into our company that speaks modern manufacturing languages and is familiar with Industry 4.0 fundamentals.”
OT and IT are Converging in Industry 4.0
According to an i-SCOOP article, “It’s impossible to talk about the evolutions in manufacturing, industrial transformation and Industry 4.0, innovations in areas such as Industrial IoT without mentioning the convergence of IT and OT.”
Historically, operational technology (OT) has referred to “a category of computing and communication systems to manage, monitor and control industrial operations with a focus on the physical devices and processes they use.”
Information technology (IT), on the other hand, “is about business and enterprise systems that store, process and deliver information.” Because Industry 4.0 technologies are becoming more and more commonplace throughout traditional OT equipment, cybersecurity becomes more critical every year.
According to Jim Molter, IT Manager – Smart Factory Deployment of Kohler Co., “Industry 4.0 is forcing us to break down those silos and start to learn to work together…that’s where we’re headed. There’s not going to be a distinction [between OT and IT] anymore.”
Educational Institutions Play a Key Role in Preparing Industry 4.0 Workers
When experts evaluate strategies for bridging the skills gap, it’s clear that educational institutions must play a key role in preparing students for Industry 4.0 careers. But can they do it alone?
The answer is no. Educational institutions must partner with industry counterparts to ensure that the knowledge and skills they’re teaching will produce students with the valuable skills that industries around the country need.
Anne Troka, Community Engagement Manager for Sargento Foods Incorporated, explains a successful approach she helped to develop called Manufacturing 4.0:
“We started conversations with…four schools and four businesses [to] build a partnership to help students — our future workforce — connect with our businesses to really get skills that we need and skills that the students will need…to make them employable in a variety of different careers, because Manufacturing 4.0 is in manufacturing as well as many other industries.”
To date, the partnership has helped to design and build five courses to prepare students for Industry 4.0 careers, including subject areas like mechatronics, industrial controls, robotics, and the Internet of Things. Eventually, students will also be able to earn SACA certifications related to their coursework. In this way, “we’re really connecting education to [career] success,” concludes Troka.
Industry 4.0 Also Requires Upskilling Current Employees
Unfortunately, employers can’t wait for the next generation of highly-skilled workers to emerge from high school or college. As Anthony Ebio, Director of Industry 4.0 Learning for Ashley Furniture Industries, Inc., noted, schools simply aren’t “cranking out the learning and the students fast enough.”
That’s why Ashley Furniture has invested heavily in upskilling its current employees so that they have the advanced skills they need to work with new Industry 4.0 technologies. Ebio noted that they used SACA certifications as a guide when setting up training for incumbent workers: “We found ourselves leveraging a lot of the SACA structure to make sure that we have [curriculum] to support Industry 4.0.”
Other companies are following suit. Ken Evans, Associate Maintenance Manager for S.C. Johnson & Son, Inc., noted that S.C. Johnson has partnered with Gateway Technical College to upskill its employees with an eye toward achieving SACA certifications.
So far both young and older employees have been excited about the prospect of learning and gaining new skills. Plus, using SACA certifications as a guide has allowed current employees to see a payoff for their hard work quickly. According to Evans, “under SACA, [current employees] can get incremental steps of recognition and be proud of it, and we’re proud of them.”
SACA Brings It All Together
If the current skills gap plaguing industries across the world is to be bridged, strategic partnerships between industry and educational institutions must be forged. Schools must begin to produce a pipeline of highly-skilled workers ready to work in an Industry 4.0 environment.
Likewise, industry must upskill its current workforce with the advanced skills needed to operate, maintain, troubleshoot, and repair the Industry 4.0 automation technologies taking over the factory floor.
According to Michael Cook, Director of Global Academic Partnerships for Platinum SACA Sponsor Rockwell Automation, Inc., “no one company can really do this alone…SACA is providing significant leadership here…ensuring that there’s a close fidelity between the academic space as well as what we find relevant in industry. That alignment is a significant part of what SACA brings.”
To learn more about Industry 4.0 certifications and how SACA can help both educational institutions and industry employers begin the task of bridging the Industry 4.0 skills gap, visit the SACA website and then contact SACA for more information.
- Published in News
Can Smart Manufacturing Transform the Food Industry?
What types of products do you buy online? Today, the answer to that question for many people is just about anything and everything. Things haven’t always been that way, though.
In the earliest days of e-commerce, consumers got their feet wet in the online marketplace purchasing products that were known quantities that could be shipped safely and cheaply. More personal items, such as clothing and shoes, retained a foothold in brick-and-mortar stores where customers could try things on to ensure a good fit.
Fast forward to today and it’s easy to see how drastically e-commerce has changed the retail landscape. Some people now purchase all of their goods exclusively online. There are still certain areas, though, where e-commerce has been slow to gain traction. For example, the food industry has yet to replace a trip to the grocery store with an online experience…until recently.
The COVID-19 pandemic changed much about how we live our lives, including that once-simple trip to the grocery store. Now, more and more people are doing their grocery shopping online or via a smartphone app and having their groceries delivered directly to their car at the store.
As a result, the food industry finds itself in need of a transformation to respond to changing realities driven by consumer demand. Experts believe that transformation will come through a variety of new smart manufacturing technologies.
Consumer Demand Driving Changes
When the COVID-19 pandemic began in early 2020, no one fully understood the ways in which our lives would change over the course of the coming months. Routine, everyday tasks, such as shopping for groceries, were suddenly fraught with the potential for exposure to the deadly virus.
Retail grocers were faced with simultaneously managing intense supply chain disruptions that left many shelves bare and customers who wanted as little contact with other shoppers as possible. The solution for many was to pair online shopping (often via an app) with curbside delivery.
Shopping for food online was a new experience for most customers. It didn’t take long, however, for most people to figure out that they could compare prices across various stores just like they would for any other online purchase.
The effect of these changes on the food industry has been significant. As author Katy Askew notes in a recent FoodNavigator article, the food industry is being forced “to rapidly adapt their processes and products to keep up with changing markets” resulting from “elevated consumer expectations.”
Smart Manufacturing to the Rescue
How can food and beverage companies keep up with these rapid changes? Askew spoke with Andrew Smith, Regional Segment Leader – Process & Packaging OEMs at Rockwell Automation, which recently became a Platinum Member of the Smart Automation Certification Alliance (SACA).
According to Smith, “To remain competitive, food and beverage manufacturing systems must optimize productivity and perform at the highest standard. This requires comprehensive and continuous operations improvement.” Increasingly, the food industry is turning to smart manufacturing to achieve those goals.
Smith believes in the potential of smart manufacturing:
“Connected, information-enabled manufacturing – or smart manufacturing – can make all the difference. New technologies are helping food and beverage manufacturers better understand and use their food processing operations. Smart manufacturing can help improve asset utilization, increase yield, drive workforce productivity, optimize resource management, and mitigate security risks.”
Not convinced yet? Smith points to Hillshire Brands as a prime example of what smart manufacturing can do. After the company began using a manufacturing intelligence system at a Texas plant, “the food manufacturer reduced inedible product and waste goals to 0.8% – saving about 5.5 million corn dogs per year.”
Technologies Changing the Game
The impact of smart technologies is not lost on the average person today. Whether it’s the smartphone in your hand or the smart thermostat keeping your home the perfect temperature, nearly every aspect of life has been impacted by advances in technology
Modern manufacturers are no exception, including food and beverage companies. According to Smith, “New developments in technology are redefining food and beverage manufacturing. By combining the Internet of Things, wireless and mobile technologies, data analytics, and network infrastructure, companies can access and act on the data from their operations before a potential problem arises.”
Askew notes in her article that Smith identified five advanced technologies he believes will drive greater adoption of smart manufacturing technologies in the food industry:
Flexible Manufacturing
Flexible manufacturing focuses on how quickly a company can adapt to change. As Matt Graves and Rachel Wilson explain in an article on the Rockwell Automation blog, “It’s about creating a seamless flow from need to delivery. True flexibility empowers manufacturers to stay in tune with their market, by replacing rigid and static operating models with levels of control and responsiveness never previously thought possible.”
When it comes to integrating new technologies, though, the authors stress that companies must not forget about the people using those technologies:
“When it comes to embracing Industry 4.0, integration between departments is key. While new technology can bring data and systems together, getting your people to communicate/collaborate is just as important – and absolutely essential if you want to gain the maximum return on investment.”
Augmented Reality
As Askew notes in her article, “Augmented reality (AR) is a technology that allows users to view and interact with real-world environments through computer generated superimposed images. It enables workers to perform better and avoid safety and compliance risks by providing easy access to the information they need online.”
In smart manufacturing, companies use AR to help technicians troubleshoot problems in real time. For example, maintenance personnel can use an AR app on a smartphone or tablet to zero in on exactly what component of a machine may be malfunctioning and develop a solution more quickly, thereby reducing equipment downtime.
Predictive Maintenance
The heart of smart manufacturing is the collection, processing, analysis, and application of the tremendous amounts of data (sometimes called “big data”) generated by the production process. According to Askew, companies will use “powerful machine learning algorithms and predictive analytics software to offer predictive and prescriptive maintenance.”
Practically, this means that machines equipped with smart sensors can monitor their own performance. Technicians will receive alerts from machines when maintenance needs are imminent, allowing them to maintain and repair equipment before breakdowns occur, thereby reducing downtime and increasing productivity.
Edge Computing
A Rockwell Automation article explains edge computing in this way:
“Edge computing combines a machine’s control and computing hardware into one platform, either with a controller that has a built-in computer or with a computing module that sits on the same rack as the controller. With this two-in-one approach, you can put all your machine’s digital content — such as custom code, the controller’s human-machine interface (HMI) application and any third-party software programs — right where the controller resides, rather than in another location. This creates inherent benefits for end users, including space savings and access to data right at its source. But it also creates new opportunities for you to build entirely new solutions for production applications.”
According to Askew, “Edge computing will complement existing cloud infrastructure by enabling real-time data processing where work is done (for example, motors, pumps, generators, or other sensors). Implementing integrated analytics from the edge to the cloud will help these companies maximize the value of investments in digital systems.”
Digital Twin/Digital Thread
In addition to augmented reality apps, companies are also using advanced digital tools to assist with troubleshooting, such as digital twins and the Digital Thread. According to Askew, a digital twin is “the collection of data created in software representing a real-life system. Machines, controllers, processes, workflow, and any other aspect of a system can be represented digitally, without any interruption to ongoing activities.”
Similar to a digital twin, the Digital Thread “creates a virtual representation of how data travels within a company. The Digital Thread enables supervisory enhancements throughout the supply chain, including delivery of work instructions to operators, quality control sampling, and automated activation of components and materials from vendors, suppliers, and partners”
What can these technologies do for the food industry? Askew paints an interesting view of a future that’s probably a lot closer than we think:
“In the near future, we will see that by interconnecting business systems through the Digital Thread, companies will practically start up new production lines. Using the digital twins, manufacturers will run machines virtually before parts are ordered, discover control issues before support personnel review them, predict future performance challenges and opportunities, simulate line changes to stay keep up with changing customer demands, and will train new staff in non-stop systems of activity.”
SACA Certifications Validate Industry 4.0 Skills
Employees in the food and beverage industry would do well to complement their current skillset with advanced Industry 4.0 skills that will help them change and grow with advances in technology. For those workers wanting to specialize in Industry 4.0 technologies, the certifications offered by the Smart Automation Certification Alliance are a great place to start. SACA offers industry-standard certifications that focus on “connected systems” skills. To learn more about the different types of SACA certifications, visit SACA online.
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Industry-Recognized Apprenticeship Programs: IRAPs Promise New Opportunities
LOUISVILLE, KY—OCTOBER 14, 2020
Industries across the United States have been struggling for years to fill open positions with qualified workers. Despite widespread recognition of the problems industries face, the skills gap has continued to widen.
Rather than bringing new solutions, 2020 instead saw a global pandemic make an already-tough jobs situation worse. Due to the COVID-19 crisis, millions of American workers have lost their jobs, many of them permanently.
As the U.S. seeks to recover from “the most devastating economic crisis since the Great Depression,” there is no shortage of problems that must be addressed and solutions that need to be formulated. How effective those solutions are will dictate the speed and scope of economic recovery.
Unlike past economic recovery initiatives that often pushed people toward college degrees, experts believe that our current economic recovery from the COVID-19 Recession must instead focus on practical skill development for jobs industries need. To that end, community colleges and skills training may play a critical role.
Another potential solution with a proven track record of success is apprenticeship. In fact, many believe new industry-recognized apprenticeship programs (IRAPs) will provide fresh opportunities for both American workers and industries that desperately need skilled talent. How? IRAPs will expand the use of the apprenticeship model to industries that haven’t used it or have underutilized it in the past.
What Are IRAPs?
So what exactly are IRAPs anyway? According to the U.S. Department of Labor’s (DOL) Apprenticeship.gov website:
“Industry-Recognized Apprenticeship Programs are high-quality apprenticeship programs recognized as such by a Standards Recognition Entity (SRE) pursuant to the DOL’s standards. These programs provide individuals with opportunities to obtain workplace-relevant knowledge and progressively advancing skills. IRAPs include a paid-work component and an educational component and result in an industry-recognized credential. An IRAP is developed or delivered by entities such as trade and industry groups, corporations, non-profit organizations, educational institutions, unions, and joint labor-management organizations.”
For example, the Smart Automation Certification Alliance (SACA) was recognized as one of 18 initial organizations designated as an SRE by the DOL on September 23, 2020. SACA may now evaluate and recognize IRAPs consistent with DOL standards.
What are those standards? According to the DOL’s IRAP Fact Sheet, high-quality IRAPs must meet the following 10 requirements:
- Paid Work
- Written Training Plan
- Written Apprenticeship Agreement
- Specialized Knowledge and Experience
- Safety
- Equal Employment Opportunity
- Credit for Prior Knowledge
- Mentorship
- Industry-Recognized Credentials
- Disclosure of Costs and Fees.
When Were IRAPs Created?
IRAPs are a relatively-new solution in the area of workforce development. Their history can be traced back to June 15, 2017, when President Trump issued an Executive Order to Expand Apprenticeships in America.
According to a DOL press release, the order established the 20-member Task Force on Apprenticeship Expansion, which was “headed by the Secretary of Labor and co-chaired by the Secretaries of Commerce and Education.”
The DOL’s IRAP Fact Sheet notes that the president’s order “directed the Secretary to consider proposing regulations that promote the development of apprenticeship programs by third parties…especially in sectors where apprenticeship programs are insufficient.”
The Task Force subsequently recommended the establishment of IRAPs in May 2018. Eventually, as the IRAP Fact Sheet notes:
“To address America’s skills gap and to rapidly increase the availability of high-quality apprenticeship programs in sectors where apprenticeship opportunities are not widespread, the [DOL] has issued a Final Rule that establishes a system for advancing the development of high-quality IRAPs.”
IRAPs then became official when new regulations took effect on May 11, 2020.
How Do IRAPs Differ from Traditional Apprenticeships?
According to a recent Forbes article by Ryan Craig:
“For years, policy makers have struggled with the question of how to expand apprenticeships from traditional blue collar building and industrial trades to fast-growing sectors like technology, healthcare, and professional services. On a per capita basis, the U.S. is far behind other nations: Germany has nearly 20x as many apprentices, and the UK has 14x.”
Craig further notes that the goal of IRAPs is:
“to increase the number of actual American apprentices from 500,000 to 5 million by decentralizing apprenticeship authority from the DOL to hundreds of third party IRAP authorizers [SREs]…The expectation is that while DOL registered apprenticeships are infamous for the amount of paperwork required, IRAPs will be much less onerous and therefore more popular.”
Rather than taking apprenticeships in an entirely new direction, IRAPS are “intended to run in tandem with the department’s long-established registered apprenticeship program,” according to an article from the Community College Daily website. Indeed, the DOL’s IRAP FAQ clearly notes:
“IRAPs and RAPs [Registered Apprenticeship Programs] will work on parallel tracks with the support of the Department. The Registered Apprenticeship system has produced successful results in many industries for over 80 years and it will continue to do so. The industry-led, market-driven approach outlined in the IRAP final rule will give employers and other stakeholders the additional flexibility necessary to expand the apprenticeship model into new industries where registered programs are less prevalent and to address the diverse workforce needs of different industries and occupations. IRAPs provide a new apprenticeship pathway that lets industry organizations take the lead in identifying high-quality apprenticeship programs and opportunities based on the needs in their industry.”
Consistent with the goal of expanding the apprenticeship model to new industries, one notable difference between IRAPs and RAPs is that SREs are prohibited from recognizing IRAPs in the construction industry. According to article by Katie Spiker from the National Skills Coalition:
“This carve out was…the subject of a massive campaign by the building trades unions…According to proponents of the construction industry exclusion, and the Department in their justification of excluding construction in the final IRAP rule, the fact that the majority of U.S. apprenticeships are in the construction industry is evidence the model is effective for the industry and that expanding IRAPs to construction is not necessary to meet the goal of expanding apprenticeships in the U.S.”
Who Will Benefit from IRAPs?
The DOL clearly outlines a set of expected benefits to both workers and businesses in its IRAP Fact Sheet. For businesses, the DOL expects IRAPs to:
- provide an additional pathway to assist career seekers and job creators;
- serve the needs of business by expanding apprenticeships across more industries;
- use innovative, industry-driven approaches to scale a proven workforce education model;
- allow more flexibility to design apprenticeship programs that meet business needs; and
- supply an immediate pool of workers for today and skilled talent for tomorrow.
For workers, IRAPs are expected to:
- offer opportunities to earn and learn, while obtaining valuable, portable, industry-recognized, competency-based credentials;
- provide training in standards that are developed by the industry, ensuring an apprentice develops the skillset needed for career success;
- increase the opportunities for apprenticeship programs across all sectors in the economy; and
- provide an alternative to college for finding career success that allows workers to obtain high paying jobs without going into debt.
Katie Spiker echoes the view that both workers and businesses should benefit from IRAPs: “The IRAP initiative is evidence of the need to modernize apprenticeship, expand access to workers to earn industry-recognized credentials and allow businesses to play more of a role in helping tailor the kind of training their workers receive to meet their specific needs.”
While traditional registered apprenticeship programs have been successful for years, Roy Maurer notes in a recent article for SHRM, the Society for Human Resource Management, that “only about 0.2 percent of the U.S. workforce has taken advantage of the programs, primarily in trades and construction.” The DOL believes IRAPs “will effectively expand apprenticeship in telecommunications, health care, cybersecurity and other sectors where it’s currently not widely used.”
Rachel Greszler, senior policy analyst at The Heritage Foundation, believes the benefits to workers are clear:
“The [IRAPs] rule is an important step in opening up more nontraditional and affordable education opportunities that could particularly benefit younger Americans who have been left behind by America’s higher-education system, as well as current workers who have been negatively impacted by changes in industry and technology. It’s not in everyone’s best interest to pursue an expensive four-year college education, and these types of apprenticeships make it possible for individuals to obtain the education they need for a promising career without taking on debt, and instead, actually being paid in the process.”
As U.S. Labor Secretary Eugene Scalia summarized in a DOL press release:
“As workers seek to reenter the workforce following the economic disruption caused by coronavirus, [IRAPs] and the SREs that recognize them will provide new opportunities for Americans to earn a living while learning the skills needed in a changing job market.”
Where Can I Learn More About IRAPs?
According to Ryan Craig:
“There are millions of unemployed workers whose jobs are unlikely to return once the pandemic subsides. So one of the most important policy questions in America today is how they’ll find paths back to work…If there is an answer, apprenticeships will almost certainly play a leading role.”
If you want to learn more about IRAPs and the SREs who will be helping to bring them to life, be sure to check out the DOL’s Apprenticeship.gov website. The latest information and developments will be posted there as IRAPs take shape and begin to fulfill the goal of expanding apprenticeships into new industries while helping workers gain new skills.
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Macomb Community College Joins SACA to Provide Students with Industry 4.0 Certifications
LOUISVILLE, KY—AUGUST 17, 2020
The Smart Automation Certification Alliance (SACA) is pleased to announce that it has recently entered into an agreement with Macomb Community College and ATS Midwest to support the college’s efforts to align its education and training to meet the realities of Industry 4.0. Students completing Macomb’s advanced manufacturing programs will soon earn SACA certifications, giving them a competitive advantage in today’s job market.
Today’s students face a far different world of advanced manufacturing than existed a decade ago. While automation technologies have been commonplace for many years, the Internet has brought about a convergence of new “connected” technologies that is revolutionizing how products are made.
Known as the Fourth Industrial Revolution or Industry 4.0, this latest disruption of the advanced manufacturing world is resulting in reduced downtime and increased quality, productivity, and overall efficiency in industries of all kinds thanks to advanced technologies that make up what is known as the Industrial Internet of Things (IIoT).
IIoT technologies include such things as advanced robotics, machine learning, artificial intelligence, autonomous vehicles and machines, cloud-based data analysis, and cybersecurity. As companies increase their use of networks and Internet technologies, they are connecting more devices, from smart sensors to smartphones.
As a result, these highly-connected systems require new skills in almost every occupation. To succeed in an Industry 4.0 environment, current workers and today’s students must learn to interact with software, data, networks, and smart devices.
While there are many certifications available today that address isolated competencies, from machining to maintenance and information technology (IT), SACA certifications are different. SACA’s Industry 4.0 certifications certify “connected systems” skills that address the integration of the many types of advanced manufacturing technologies with Industry 4.0 technology.
SACA’s Industry 4.0 certifications have been developed for industry by industry through a rigorous process that began with the creation of truly international skill standards. These standards have been endorsed by leading experts in Industry 4.0 technologies around the world.
Working with forward-thinking institutions like Macomb will enable SACA to accomplish its vision to provide highly-affordable, accessible Industry 4.0 certifications that significantly increase the number of individuals who possess the skills represented by these credentials.
The result will be an increasing number of students prepared to be successful in an Industry 4.0 world, as well as more companies that have the highly-skilled workers they need. Don Hutchison, Macomb’s Dean of Engineering and Advanced Technology, agrees:
In southeast Michigan, industry already needs employees who understand how advanced manufacturing systems integrate. At Macomb, we are listening to industry and creating training for individuals and industry that meets the challenges and opportunities of Industry 4.0. Arming Macomb’s graduates with SACA certification signifies to employers that they are prepared to successfully navigate the complex, integrated nature of today’s manufacturing environment.
Fortunately, Macomb also enjoys the support of local industry. Tom Kelly, Executive Director and CEO of Automation Alley, Michigan’s leading manufacturing and technology business association and Industry 4.0 knowledge center, supports Macomb’s vision:
It is encouraging to see Macomb Community College commit to Industry 4.0 training, which will help to ensure industry receives graduates with employable skills. Today, technology is moving at an accelerated pace which requires a new set of working skills. If our state is to keep pace and maintain a global leadership position in manufacturing, we must transform and continuously develop our talent pipeline.
SACA looks forward to a long relationship with Macomb as they, together with industry partner ATS Midwest, begin a thorough review of all of the college’s advanced manufacturing programs to ensure SACA certification requirements are incorporated into the programs’ core curricula. The parties will also be reaching out to local industry to confirm that SACA certification requirements reflect the skills needed by industry. For more information about SACA and how its Industry 4.0 certifications can prepare your students for the jobs of the future, visit SACA.org or contact SACA Executive Director Jim Wall.
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Indiana Governor’s New Initiative Offers Free SACA Silver Certifications for Hoosiers
During Indiana Governor Eric Holcomb’s June 5, 2020 press conference, a new state initiative was announced that will offer 10,000 free credentials to Indiana residents that have been dislocated from their jobs due to the COVID-19 pandemic. The Smart Automation Certification Alliance (SACA) is one of the organizations offering credentials to displaced Hoosier at no cost. SACA’s certifications are task-based and nationally recognized in preparing individuals for rewarding careers working with advanced manufacturing and Industry 4.0 technologies.It’s no secret the immense role that Industry 4.0 is expected to play in the future of industrial manufacturing.
These courses can be taken online and feature virtual simulation of industrial applications, which make them ideal for preparing users for the workplace. The online delivery also allows users to practice social distancing guidelines to help prevent the spread of Coronavirus.
Ivy Tech will coordinate enrollment of new students while Amatrol and Aidex will help to promote this opportunity to displaced Indiana residents seeking a new career path. Amatrol will also provide free access to its Learning Management System (LMS) for students enrolled in this program.
When a student completes one of the six courses, they will be eligible to sit for the associated SACA Silver Credential. SACA Silver Credentials are completed solely online while Gold Credentials involve hands-on skill demonstrations. Students are eligible to earn all six SACA Silver credentials.
People interested in these opportunities can visit YourNextStepIN.org, which is part of Indiana’s Rapid Recovery for a Better Future initiative. Lubbers said, ““Visitors to the site can talk to a real person to answer questions and help them determine the right path forward and the training options that will help them achieve their goals. These partners and tools help to connect Hoosiers to opportunities — some that already exist — and we will continue to build on these connectors in the weeks and months ahead.”
The free courses and associated SACA Credentials are as follows:
Production Operations Technician
- Certified Industry 4.0 Associate I (C-101): Students will study Industry 4.0 concepts, safety, quality, technical drawings, machine operation and maintenance, and hand tools.
- Certified Industry 4.0 Associate II (C-102): Students will study manufacturing systems performance, mechanical and fluid power systems, programmable controller systems, CNC and additive manufacturing, system communications, and mechatronics.
Multi-Skill Maintenance Technician
- Electrical Systems 1 (C-201): Students will study electrical system safety, electrical schematics and diagram, taking electrical measurements using a digital mustimeter (DMM), combination circuits, electrical circuit troubleshooting, and inductive and capacitive circuit analysis.
- Electric Motor Control Systems 1 (C-202): Students will study electric motor safety, ladder logic schematics, how to properly ground connections, transformer selection and installation, how to connect and operate a 3-phase motor, and how to connect and operate a variety of electric motor circuits including manual motor, 2/3 wire magnetic motor starter, reversing motor control, hands-off-auto motor control, and basic timer control.
- Motor Control Troubleshooting 1 (C-204): Students will study how to troubleshoot motor control components, use a clamp-on ammeter to measure motor current, and troubleshoot a variety of motor control circuits and an AC VFD motor control system.
- Pneumatic Systems 1 (C-209): Students will study pneumatic system safety procedures, pneumatic schematics interpretation, how to connect and adjust pneumatic supply lines, how to start up and shut down a reciprocating air compressor, how to connect and operate basic pneumatic circuits, how to monitor system operation, pressure and force, and how to perform basic system servicing.
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The Importance of a Smart Automation Certification
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