3 Minutes Read

Reduce Unscheduled Downtime and Improve EHS Compliance with Mobile Operator Rounds

Detecting faulty equipment early made it easy! Schedule a live demo to see how you can save $1M monthly and increase safety
Schedule a Demo

Downtime and environmental, health and safety (EHS) compliance cost industrial manufacturing and process plants serious money, harming already thin profit margins, negatively impacting stakeholders and investors, and cutting into front-line worker morale. Daily operator rounds from plant maintenance technicians identify potential issues before they become problems. However, paper-based inspections often fail to provide accurate, timely information for decision makers to assess risks, prioritize assignments and take remedial action. Mobile operator rounds — using hand-held digital devices such as smartphones and tablets — offer a flexible, agile and dynamic solution to manual paper inspection problems.

Mobile Operator Rounds to Combat Unplanned Downtime and Missed Production

The average manufacturing plant suffers 800 hours of unscheduled downtime every year, equaling nearly 15.5 hours every week. This is no small figure when you consider the typical automotive plant loses $22,000 per minute when production stops. A 15-minute shutdown (the length of a coffee break) could run $330,000 in missed production, lost revenues and wasted resources. Unplanned downtime costs plants a combined estimated $50 billion every year.


Roughly 10% (and maybe even less) of industrial equipment ever actually wears out. The overwhelming majority of mechanical failures within a plant are avoidable. Poorly executed manual operator rounds either miss the signs of these potential failures before they occur or don’t warn decision makers in enough time to take proper pre-emptive action. 

That’s because manual, paper-based inspection programs limit visibility. Decision makers are stuck in information silos. They have no way of knowing the status or condition of vital plant production equipment outcome until paper inspection checklists are turned in or manually uploaded into the back-office system. 

Mobile operator rounds improve the inspection data collection process, enabling technicians to gather accurate, mission-critical information in less time. Information is immediately uploaded into the back-office system because data capture and sharing is digital, letting decision makers view inspection results in real time.

Better EHS Compliance Using Mobile Operator Rounds

The National Association of Manufacturers (NAM) calculates that environmental and safety regulations cost the average manufacturer an estimated $10,497 per worker. These costs are higher for small companies.

In 2019, the Environmental Protection Agency imposed $471.8 million in combined federal administrative and judicial civil penalties and criminal fines. The agency also charged 137 criminal defendants, up 22% from 2018. 

Agencies and the politicians that create EHS rules and regulations are becoming sensitive to desires for a cleaner environment. They have heard pleas for a safer workplace. Worker health has become a priority not only for politicians and regulators, but for the plants themselves to the ongoing COVID-19 crisis.

Manufacturers need ways to better identify threats and assess risks. They’re seeking ways to mitigate exposure, improve their ability to comply with a myriad of ever-more-complex regulations and overlapping agencies and limit the potentially negative consequences of fines, sanctions and penalties.

A mobile operator rounds solution improves the accuracy, thoroughness and timeliness of daily EHS compliance inspections. Digital forms are faster to complete than outdated, error-prone paper checklists. They enable technicians to gather more data with fewer information gaps and be shared with decision makers in real time so that proper remedial steps can be quickly taken to correct the situation.

Mobile Operator Rounds: Flexible, Accurate and Timely

How does a mobile operator rounds solution work? Simply put, hand-held mobile devices (smartphones, tablets, wearables, etc.) replace paper checklists and binders. Technicians access digital forms on their device to conduct the round. These digital forms are dynamic, unlike paper checklists, meaning they can be quickly and easily changed on the fly to better meet a plant’s situational needs.

A mobile operator rounds solution can be customized as needed so a technician can’t proceed to the next inspection area without completing all the necessary steps for the zone in which he or she is currently working. This results in more thorough and complete inspections for equipment maintenance and EHS compliance versus a traditional paper checklist. 

Technicians scan equipment barcodes and complete the digital form by checking customized data fields to indicate the present operational status and safety condition. That information is immediately uploaded electronically into the back-office system. 

No one has to wait until the end of the round or later to access this critical data. Everything is shared in real time. Decision makers can view inspection information on their own mobile device or on a desktop app. They can also communicate and collaborate with the technician as he or she is conducting the round. 

This capability means nothing is overlooked, questions or concerns can be instantly addressed, risk and threat levels quickly ascertained, and action taken before downtime is incurred or a safety threat emerges. 

Ready to Learn More about Mobile Operator Rounds?

Innovapptive is a pioneer in the development of Connected Worker solutions that empower plant front-line workers to get their jobs done faster, better, cheaper and safer. Our Mobile Operator Rounds delivers a streamlined data collection process, gives technicians and decision makers greater agility and flexibility to share information and collaborate in real time, reduces downtime and mitigates safety risks. Click here to schedule a free demo, or call us at 844-464-6668.

New call-to-action
How Visual Planner Helps With Maintenance Planning
“Proper planning and preparation prevents poor performance.” Stephen Keague, author A plant maintenance planner occupies an important position on...
Read More
Three Ways Innnovapptive’s Connected Worker Platform Transforms Maintenance and Operations
Smart machines are conquering factory floors in Industry 4.0 but unpredictable situations in manufacturing still need human intervention from...
Read More
A Simpler Way to Measure ROI for Digital Work Instructions
Digital work instructions ensure quality and continuity in production while creating safer workplaces. It’s critical to thoroughly evaluate your...
Read More
Measuring ROI of Enterprise Mobile Solutions
Mobile technologies can be transformative for your frontline workers, giving them real-time access to the ERP data they need to make proactive...
Read More
A‌ ‌Better‌ ‌Way‌ ‌to‌ ‌Measure‌ ‌ROI‌ ‌for‌ ‌a‌ ‌Mobile‌ ‌Operator‌ ‌Rounds‌ ‌Solution‌
Operator rounds are only as good as the experience and knowledge of the technician performing them. A new, younger generation of technicians lacking...
Read More
Five Key Benefits of Digital Operator Rounds and Inspections
Plants struggling with excessive downtime or safety compliance have a powerful new instrument they can add to their toolboxes. Digital Operator...
Read More
Three Distinct Features That Set Innovapptive’s Operator Rounds Apart
Operator rounds play a key role in maintaining equipment reliability, sustainable productivity and occupational safety.  Efficiency of operator...
Read More
Using Digital Work Instructions to Boost Your Plant’s ISO Certification Efforts
You want to show customers, employees, stakeholders, partners and lenders you can make the grade when you’re an industrial process plant or...
Read More
Reduce Unscheduled Downtime and Improve EHS Compliance with Mobile Operator Rounds
Downtime and environmental, health and safety (EHS) compliance cost industrial manufacturing and process plants serious money, harming already thin...
Read More