Global Lighthouse Network 2025

Similarly, because frontline operators serve as the touchpoint to production, they must be armed with user-friendly decision-making and troubleshooting tools. Lighthouses know that what matters most is not the model or the algorithm, but rather how effectively the intended user will interact with it. That means designing intuitive interfaces that people will engage with in their daily tasks and flows where operators play an active role in problem-solving and issue resolution. Investing in the workforce Since 2020, Lighthouses have dedicated an average 10% of their use case portfolio to workforce priorities, including worker experience, skill development, safety, skill augmentation and work augmentation.44 These Lighthouses have achieved an average 10-20% reduction in non- value-added tasks and 25-30% improvement in labour productivity.45 What is interesting about Lighthouses is their holistic approach – with more than 75% of them deploying solutions that span all dimensions of the frontline experience (see Figure 13). Lighthouses know that what matters most is not the model or the algorithm, but rather how effectively the intended user will interact with it. Frontline use cases at Lighthouses FIGURE 13 1. Examples from original publication of Global Lighthouse Network Research Survey, published July 2024 Source: Global Lighthouse Network In one skill development use case example, CEAT in India improved overall equipment effectiveness (OEE) by 16p.p., addressing losses due to minor stoppages by connecting their performance management system with operator training curricula. They leverage actual performance data to generate personalized learning programmes in virtual reality (VR) for faster, targeted reskilling. They see this training as a two-way street, collecting feedback from operators on why processes may be difficult to execute, including ideas for improvement.46 In a safety example, Sanmen Nuclear Power combined digital twin with physical and digital simulation technologies to imitate emergency response scenarios. The solution has accelerated the training process, which traditionally took at least five years to qualify a reactor operator and has reduced incidents due to human error by 88%.47# of applications by domain of impact Illustrative example1 Worker experience 93 Skill development 87 Safety 73 Skill augmentation 70 Work augmentation 56 Remote connect ion tools Physical enablement tools Mixed reality (AR, VR, MR)Digital information platforms Inclusivity & well-being tools Performance & safety managementA renewable energy company implemented a digital engagement platform that encourages employees to share thoughts and challenges and leverages AI-generated insights A mining organization implemented a technical training centre which has decreased time to train qualified manpower for new positions and made the workforce more versatile A global industrial manufacturing organization implemented technology-enabled ergonomics assessments which reduced workplace musculoskeletal injuries and time for case evaluation by 83% An international CPG organization developed wearables to support training and upskilling , which has improved OEE by 53%, reduced non-value-added tasks by 56% and reduced scrap by 26% at one site An automotive manufacturer implemented AR/VR to remote-connect experts to shop floor paint technicians, with training programmes customized for individual areas of improvement that helped reduce defects per unit and improve OEE EXAMPLE CEAT and Sanmen Nuclear Global Lighthouse Network: The Mindset Shifts Driving Impact and Scale in Digital Transformation 22