When it comes to paperless manufacturing, dramatic scenarios of barely manageable masses of paper and impenetrable paperwork are often painted. However, we can say from experience that things haven't looked that dramatic in most companies for a while now.
However, some relevant processes are still paper-based and therefore incompatible with the requirements of digitization. Not to mention that paper-based processes always mean more time and effort and entail a higher risk of errors and loss of information.
In concrete terms, you will often still find paper in production
in accompanying documents and delivery notes
The disadvantages in production are the same as with any analog, i.e. paper-based, information carrier:
Let's get a little more specific and take a look at a recent study on paperless manufacturing. In the Digital Office Index 2024, Bitkom analysed the digitalization of business and administrative processes in German companies. And even if the overall corporate processes are considered here and non-manufacturing sectors were also surveyed: The results provide a clear overview. This is the state of paperless processes in companies:
The study shows what we already suspected: The paper deserts no longer exist, but there is still considerable potential in processes that are still paper-based.The goal of paperless manufacturing is actually already in the name: It's about manufacturing without printouts or paper-based documents. But if we look one level deeper, there is much more to it. After all, replacing a sheet of paper - let's say - with a PDF file is not the answer. Sure, the paper is gone, but instead there are now countless files lying around that are just as prone to errors, become outdated and make it difficult to reuse data.
So let's add: paperless manufacturing means eliminating paper from production in favor of end-to-end digital processes and systems. "Consistently digital" is the key here, because only then can the data that was previously stored on paper be used directly and in real time for documentation, further processing or other services. This also includes direct digital interaction and feedback options for your employees in production.
Well, that all sounds great, doesn't it? Then just throw away all the paper and off you go. If it were that easy. As always, you need to create the conditions for paperless manufacturing (if you haven't already done so in some form). Let's take a look at this from a technical and an organizational perspective. Let's start with the technology.
The right software is the be-all and end-all. Unfortunately, however, it is almost impossible to recommend or even name the one system that will solve your paper worries. As is so often the case, it depends on your requirements. Possible software solutions could be
The selected software often requires adequate hardware support and not every workstation is already equipped for digitalization. A worker assistance system, for example, also requires a screen to display digital work instructions to the employee. Other hardware investments can also be useful on the way to paperless manufacturing:
Without going into too much detail: Does the WLAN reach every last corner of the factory floor? And if not, is that a problem for the use of your future digital system? The right IT infrastructure is also an essential prerequisite for successful paperless manufacturing. This includes Internet availability as well as IT security.
When it comes to paperless processes in production, a worker assistance system is a valid solution. Paper documents or inefficient file formats such as Excel or PDF are often still used, especially where manual work is carried out. And this is precisely where a worker assistance system can come in and create digital consistency and efficiency. Let's take a look at our weasl system and see the concrete benefits: