Technology Trends


What Causes the Skills Gap?


The average cost HR managers say they incur for having extended job vacancies is more than $800,000 annually,” according to a CareerBuilder survey in 2017. 

Since 2017, the unemployment rate has skyrocketed. The economic downturn in March caused profit loss for many businesses, even without the added cost of job vacancies. 

While the economy has started to recover, businesses are increasingly struggling to fill job vacancies. The issue isn’t finding candidates to fill these new positions, it’s finding workers that meet the qualifications necessary to do these jobs effectively.

The skills gap is the disconnect between the skills a worker has and the skills required of a worker to perform their job. In modern manufacturing, the skills gap is generally attributed to either quickly losing many experienced workers or the introduction of new technologies into a worker’s environment. 

The key to staying afloat during COVID is having an agile workforce that can adapt to rapidly changing work requirements and technologies. Unfortunately, the resources necessary to advance worker capabilities are limited. An increase in demand and major decreases in employment and retainment, in particular, have shed light on how the skills gap prevents employee effectiveness. 

Causes of the Skills Gap 

Increased Demand

Increased factory activity in the last few months has required more workers to adapt and learn new skills to meet production needs. The Institute for Supply Management stated in its index that national factory activity rose to a reading of 59.3 last month. That is the highest reading since November 2018. 

Following many months of economic downturn, renewed consumerism is fueling production. New technologies have been brought in to boost throughput, but their efficiency relies on the supply chain keeping up with inventory needs. The reduced inventory during the height of COVID put a focus on retaining profit rather than stockpiling for economic revival, understandably. 

One example of a business having issues with needed materials is Casper Sleep Inc., better known as just Casper. Mattress deliveries are being delayed because the company outsources many of its materials, which aren’t available at the same rate as orders. 

The pressure to quickly move materials is leaving little time to train workers on more efficient processes or the technology intended to do that. 

Decreased Employment

As of October 2020, the unemployment rate is 6.9%, equal to 11.1 million people unemployed, according to the Bureau of Labor Statistics. In total, manufacturers in the US employ 8.51% of the workforce (NAM). This leaves just under a million manufacturers currently unemployed. 

The manufacturing industry has also seen record increases in retirement. During the third quarter of 2020, compared to 2019, 3.2 million more people between 56 and 74 years old retired according to the Pew Research Center. Last year, about 20.3% of all manufacturers were 55 to 64 years old according to the Bureau of Labor Statistics

With a large percentage of the population out of work or retiring, businesses are moving new employees into open positions. But often, the workers brought in are from other departments, industries, or completely new to the workforce. 

Often, this results in negative effects on the bottom line. Find out more about the effects of the skills gap in our article “3 Effects of the Skills Gap on the Bottom Line.” 

The manufacturing industry needs to quickly adopt realistic solutions to the skills gap that solve both of these challenges.  

To learn how Light Guide uses AR technology on their TrainAR workbench to solve the skills gap, please contact us for more information. 


How to Assemble a Face Shield for Automation Alley’s Project DIAMOnD

Automation Alley Project DIAMOnD Face Shield Work Instructions

Automation Alley partnered with Oakland County and Macomb County to create Project DIAMOnD to keep Michigan at the forefront of innovation. The program is designed to “address the urgent need to move companies into the digital manufacturing age of Industry 4.0 as fast as possible to help improve our region’s manufacturing agility and response to future disruptions.” 

As a part of that project, businesses accepted into the Personal Protection Equipment (PPE) Resilience Grant Program can receive Industry 4.0 technology at no cost to aid current and future production challenges. This includes potentially being asked to contribute to PPE production for the state in the future. 

To produce that equipment, businesses can choose to receive a TrainAR from Light Guide Systems in the grant application. 

The TrainAR system is designed to effectively and efficiently train any worker, no matter their skill set. It is proven to improve quality, cycle time, and increase productivity for all operations that are run through its system. 

It can instantaneously switch any operation to fulfill the needs of the program. Meaning, your operations are in no way strictly tied to the program through the TrainAR. 

Watch how the TrainAR would work in a situation where the program was requested to build face shields: 

Watch Video

To apply, or find out more information about the program, go to or read our article “Automation Alley’s Project DIAMOnD Keeps Michigan’s Manufacturing Agile”. 

To find out how to request Light Guide Systems products as a part of the program, or find out more about Light Guide Systems in general, please contact us


Automation Alley’s Project DIAMOnD Keeps Michigan’s Manufacturing Agile

Automation Alley Personal Protective Equipment Grant as a part of Project DIAMOnD

Michigan is known for being an economic leader. Our history is based on our ability to create the rules and lead manufacturing into the future. But COVID-19 shed light on limits to manufacturing agility in Michigan. 

Automation Alley, partnered with Oakland County and Macomb County, created a Project DIAMOnD to keep Michigan at the forefront of innovation, at no cost.

What Is Automation Alley’s Project DIAMOnD

Automation Alley’s Project DIAMOnD is described as a way to “address the urgent need to move companies into the digital manufacturing age of Industry 4.0 as fast as possible to help improve our region’s manufacturing agility and response to future disruptions.” It brings Industry 4.0 to Oakland and Macomb counties at no cost through the Personal Protection Equipment Resilience Grant Program, which is funded by Oakland County and Macomb County.  

The project applies to small to medium-sized manufacturing companies (Small being 49 or fewer employees and medium being between 50 and 249 employees according to OECD Data) that reside in Oakland or Macomb county. In those areas, there are over 300 companies eligible for the grant.

Automation Alley notes that “Manufacturers accepted into the program will receive:

  • Industry 4.0 Equipment: participating companies will have a choice of a Light Guide Systema projected augmented reality work instructions systemor a production part capable 3D printer at no-cost. 
  • Strategic Guidance: on how to transform from legacy operations to digital manufacturing.
  • An Industry 4.0 Assessment: outlining where their business stands today and what digital opportunities best fit their needs. 
  • Connections and introductions: to state-of-the-art vendors and applied research that can help them along their path to Industry 4.0. 
  • A financial investment: will be granted to purchase Industry 4.0 and state-of-the-art digital technologies

Along with these benefits, adopting digital manufacturing technology ensures jobs are kept and created in Michigan. The current workforce needs upskill and learn new processes to keep up with the increasingly data-driven environment. New workers won’t be limited by their skillset. Technologies like augmented reality work instructions ensure a more efficient training environment where employees can immediately begin performing a new job without errors. 

Deploying Industry 4.0 through the DIAMonD project at no costincreases agility across all aspects of our economy and keeps Michigan a leader in manufacturing. 

Apply now while funding is still available. 

To apply, or find out more information about the program, go to

To find out how to request Light Guide Systems products as a part of the program, or find out more about Light Guide Systems in general, please contact us



“PPE.” Automation Alley, Automation Alley, 2020, 


Bridge the Skills Gap with Augmented Reality at Integr8 2020

Join Light Guide Systems at the virtual Integr8 conference on November 9 and 10, 2020, hosted by Automation Alley. 

The two-day conference brings a network of technology and manufacturing leaders from around the world. They will share and discuss the future tools and influences of Industry 4.0 on businesses and digitization challenges and opportunities.

Light Guide will be presenting “Bridging the Skills Gap with Augmented Reality” on Tuesday, November 10 at 1:20 PM EST. The presentation will discuss how augmented reality solutions provide retraining/upskilling for employees while improving business agility for the future.

Here is a preview of the presentation: 


General admission tickets are free and can be downloaded on the Eventbrite website

More information about the conference, agenda, and speakers can be found on the Integr8 conference website

To learn more about how COVID-19 affected reskilling/upskilling, and particularly retention and recruitment, check out our “A Safe and Efficient Restart with Augmented Reality” blog post. 



The Importance of Traceability in Optimizing Production

Light Guide Systems data traceability in optimizing production

Data collection and analysis are imperative to agile manufacturing. Looking forward, especially as production innovates, staying competitive relies on comprehending every aspect of a given process. Collecting the right data enables full traceability and understanding of your process. 

Traceability is the capability to find and verify the complete history of production parts. Everything from the moment an employee scans in to start their shift to the product arriving in receiving can be tracked, analyzed, and reported. Traceability provides a “digital receipt” of every product that goes through a given process.

Traceability puts data into context

Modern digital devices are capable of recording all kinds of data ranging from step times to operator IDs, barcode scans, vision results, gauge values, serial numbers, and the dates and times that operators began and completed work. 

On its own, this data can be cryptic and hard to understand, but with a full traceability solution, it can be compiled into reports and dashboards that give you a complete picture of your process and the individual products that pass through it.

Traceability improves quality

The reports and dashboards created as a part of your solution can provide a full traceable history of your product. Full traceability helps you to contain defective parts that were caused by a batch of raw materials, a faulty production machine, or a design defect. Once you find the first bad part, you can look up all other parts that might share the problem and proactively find and repair all affected parts. 

In addition to making it easier to identify the root cause of defects after the fact, traceability efforts also promote accountability in your process and the operators that help make that process happen. 

Having an operator scan their employee badge at the station when they start their shift, for instance, can remind them of their responsibility for making sure that they are performing their job correctly and with the care the product, and your customer, deserve.

Traceability informs better decision making

Data and reports generated to prevent defects can also be used to identify bigger problems with a process. Common problems that are found are excessively time-consuming and costly activities.

Fully contextualized data may also reveal problems that are difficult to identify with the data of a single device alone. Patterns can emerge that display challenges operators face, such as unnecessary actions that harm the ergonomics or safety of a task. 

When operators are required to perform unnecessary or overly difficult tasks, they will find ways to make the task easier for themselves, sometimes in ways that are unsafe or cause quality issues. Identifying these problems makes it easier to solve them, meaning that operators can do their work effectively and comfortably.

Traceability makes compliance possible

Some industries, such as aerospace, defense, and medical device manufacturing mandate traceability in all of their processes. It’s imperative to know where a product has been, whose hands it has passed through, and that every step of the process was performed properly and safely. 

Even in the case of industries that do not mandate traceability as a part of their regulations, having a fully traceable product promotes trust and improves the reputation of the product with its customers. 

In many cases, customers may mandate full traceability of their supplier’s processes to achieve full traceability of their products. An ability to readily comply with these mandates may make a product or business more competitive to potential customers. A fully traceable process can also be used to determine whether or not quality problems may have occurred in other parts of the supply chain, protecting suppliers from liability for problems that they did not cause.

For companies that rely on products from many suppliers, traceability requirements can allow them to better understand where the components that make up their products have been, making them better able to ensure the quality of their products to their customers.

Light Guide Systems®️ Traceability

The Light Guide Systems database collects holistic manual process data that is not available from any other software. Light Guide provides bin pick data for kitting systems, including right and wrong bin picks with timestamps. Light Guide is also the only software that unobtrusively records step and cycle data as a part of the normal production process, rather than through time studies, eliminating any discrepancies caused by observation changing operator behavior. 

Light Guide collects data from the digital devices it interacts with, such as torque tools, barcode scanners, gauges, scales, biometric scanning tools, and machine vision cameras, in addition to its own data on the manual processes at the station. This provides valuable context that can be used to provide a more complete picture of how that device was used, where, and any other data that device might provide. 

Light Guide also provides the ability to take photos and videos of the station mid-process and stores them for later reference. These photos can be used to verify the quality of a product when leaving the Light Guide Station, or as a way of verifying that the work performed at the station was completed correctly. Operators can also verify personally that the work was performed correctly, providing a digital signature, through manual confirmations and text input.

Finally, Light Guide integrates with many other systems that aggregate data collected from factory floor devices, and from there can be exported to reporting tools and data dashboards, fitting into your existing data analytics workflow.

To learn more about traceability and how to apply it to your operations, please contact us for more information. 

Current customers of Light Guide Systems can access additional tips on traceability in the Light Guide Systems Wiki account, on the Database page



How Cloud Hosting is Advancing Industry 4.0 Manufacturing

Cloud Hosting

Cloud hosting is a vital piece of the digital transformation into industry 4.0.  As a part of the LightGuideAR 4.2 updates, we can connect to the Google Cloud Platform, Amazon Web Services, and Microsoft Azure; the three main cloud service providers.

But what is it cloud hosting? Cloud hosting (better known as just “the cloud”) is a data collection system that stores information on multiple servers in secure locations around the world. It provides global accessibility and mobility of data. 

By storing data in the cloud, rather than on an internal server, it opens new opportunities for enhanced security, operational efficiency, and investment in future innovation. 

Cloud Security

An internal server requires time and labor that might not always be available. It requires constant monitoring for connectivity, security issues, and needs hardware patching, firewalls, switches, routers, etc. 

Cloud hosting puts those requirements on the hosting provider. The provider has an army of experts and resources that are trained and ready for virtually any scenario. Cloud providers routinely achieve better uptime, data loss prevention, and other metrics than on-premises systems. Plus, cloud companies can take on the liability and infrastructure to keep a good server up. They can’t lose your data because they use multiple servers that are in places that ensure internet connection. Meaning, there’s always a backup. 

Enhanced Process Efficiency

Cloud hosting also offers the benefits of saved time, ease of use, and scalability. Information from every station in a plant can be gathered in one place and compared. It is also compatible with APIs and dashboards that narrow data to view the most significant information. For example, Light Guide Systems® currently uses Power BI to dashboard data.

This view of data leads to a better understanding of operational processes. Therefore, it is easier to recognize where issues are occurring and where to minimize downtime and waste. 

You can find out more about how APIs connect to cloud hosting by reading our “LightGuideAR™ 4.2 Connects Data Remotely with Web APIs” blog post. 

Hybrid Cloud Approach

Another option for cloud hosting is the hybrid cloud approach. Light Guide Systems is dedicated to 24/7 manufacturing operations that maximize employee productivity.  While there are lots of benefits to the cloud, there is a small and inherent delay in sending and receiving data to remote servers.  Due to this delay, we remain committed to keeping our system operation local to the station.  We will push operational data to the cloud as it is generated using a separate thread that will not slow down the real-time operator interactions of the system. This hybrid approach provides the best of both worlds, maximizing both productivity and data access.

Profitable Industry 4.0 Investment

The future of industry 4.0 relies on adaptability and resilience. Cloud hosting allows you to constantly adapt and evaluate security, efficiency, and innovationwith minimum effort. 

Light Guide Systems is a leader in industry 4.0 technology by using cloud hosting to adapt to manufacturing needs. Our broad understanding of the flexibility of cloud hosting allows us to easily recognize the operational needs and maximize results. 

To learn more about cloud hosting and how it can be applied to your operations, please contact us for more information.



LightGuideAR™ 4.2 Connects Data Remotely with Web APIs


Version 4.2 of the LightGuideAR™ software introduced new capabilities with Application Programmable Interfaces (APIs) for the scalability of Light Guide data.

APIs make it easier for programs to communicate with each other, locally or globally. Think of it as a kind of translator between you and your server. Having a conversation with the server is like having a conversation over the phone, where you will get more detail. A web API is like sending a text, which gives you a more specific, straightforward set of information.

Light Guide Systems® (LGS) uses web API’s with clients to increase the scalability of a deployment, decrease the amount of specialization needed in enterprise deployments, and promote the availability of using cloud data connection processes.

Light Guide Systems recently worked with a remote Google Preferred Partner that had locations in Mumbai, India, and Southeastern Michigan. They needed to transfer data without limitations caused by language or time on a global scale. Light Guide Systems placed a machine learning algorithm on the Google Cloud Platform that connected LGS to web APIs to send the data remotely.

Now, LGS can globally connect data on any Light Guide System through web APIs. Light Guide Systems are capable of connecting to the Google Cloud Platform, Amazon Web Services, Microsoft Azure / Power BI, Siemens MindSphere, and many other platforms.

To learn more about LightGuideAR Version 4.2 or APIs, including an online demo and discussion of your potential applications, please contact us for more information.


Secure and Connect Your Data: Introducing LightGuideAR 4.2

Enterprise Data

OPS Solutions is proud to announce the release of LightGuideAR Software Version 4.2. The new features and functions of Version 4.2 advance the security and connectivity of your data and Light Guide Systems.

Our new and expanded database stores more data in real-time. Meaning, process data is automatically saved and defined, giving the exact location and time that the data originated.

Enhanced enterprise-wide compatibility allows for data from each system to be gathered and viewed from a central cloud location, leveraging industry-standard platforms such as Microsoft Azure / Power BI or Siemens MindSphere. This makes for easier data reporting, analytics, and dashboarding.

The ability to share and aggregate data from all Light Guide Systems deployed in your enterprise is paired with extensive security and traceability measures. One key traceability function is full hashing of work instructions, so you can know exactly what an operator saw at each step on every part that they worked with.  We store our process data in real-time and every variable in our system can be logged and retrieved automatically.  If you are torquing bolts, scanning barcodes, gauging parts, scanning RFID badges, flipping bits in a PLC, or taking 4k pictures of your parts, this data is stored and is readily available for analysis. It also maintains data integrity.

Other new features include simplified user experience, new communications formats, increased installation ease, and improvements to logic, vision, logging, and diagnostics.

Version 4.2, like all previous versions of LightGuideAR Software, powers all of our systems, including the Classic, Pro, SpotGuide, SightGuide, and TrainAR products. To learn more about the LightGuideAR 4.2 Software release, including an online demo and discussion of your potential applications, please contact us for more information.


Light Guide Systems Joins the World Economic Forum Global Innovators Community

Advanced Manufacturing

Wixom, Michigan, USA and Geneva, Switzerland

Today, OPS Solutions and the World Economic Forum’s Advanced Manufacturing and Production Platform are pleased to announce the selection of Light Guide Systems into the World Economic Forum Global Innovators Community.

The Global Innovators Community is an invitation-only group of the world’s most promising start-ups and scale-ups that are at the forefront of technological and business model innovation.  Amid major global disruptions brought about by the COVID-19 pandemic, it is a critical moment for innovative companies to bring forward new ideas and innovations to help protect the lives and livelihoods of communities and industries around the world.

As the Organization for Public-Private Cooperation, the Forum provides the Global Innovators Community with a platform to engage with public- and private-sector leaders and to contribute new solutions to overcome the current crisis and build future resiliency.

Francisco Betti, Head of the Advanced Manufacturing and Production Platform at the Forum stated, “We welcome Light Guide Systems to the Global Innovators Community and to our Platform for Shaping the Future of Advanced Manufacturing and Production.  At the forefront of Augmented Reality in manufacturing, Light Guide represents game-changing technology that is empowering the manufacturing workforce to take quality, productivity, and efficiency to new levels. Innovative voices such as Light Guide Systems are essential in the work we do and we look forward to Light Guide’s contributions to our community.”

Light Guide Systems CEO and President Paul Ryznar stated, “We are very pleased to be selected to WEF’s Global Innovators Community.  We are already engaged with the Forum in critical initiatives to assist in COVID-related economic recovery efforts as well as bringing our Augmented Reality technology to help unlock human potential in manual manufacturing environments within underdeveloped countries.  It is meaningful work and we are passionately committed to ensuring success for the manufacturing workforce.”

About Light Guide Systems:

Light Guide Systems (and parent company OPS Solutions) have created a portfolio of patented Augmented Reality products which use proprietary software to provide visual workflow and confirmation of complex manual processes. For applications including material handling and logistics, assembly, test and inspection, and training, Light Guide Systems technology provides the visualization, traceability, and flexibility for leading companies globally. Key markets include automotive, aerospace and defense, heavy truck and industrial equipment, food preparation, and medical equipment manufacturers and service providers. Light Guide System is headquartered in Wixom, Michigan, USA with our European offices in Prague, Czechia, and Asia Pacific offices in Suzhou, China. Learn more at or

About the World Economic Forum:

The World Economic Forum, headquartered in Geneva, Switzerland, is the International Organization for Public-Private Cooperation.  The Forum engages the foremost political, business, cultural and other leaders of society to shape global, regional and industry agendas.  To learn more about The World Economic Forum, visit



LightGuideAR for PPE and Health Screening Confirmation

Health Screening

As manufacturing and service companies restart their operations following long shutdowns due to the COVID-19 pandemic crisis, there are several critical elements where Augmented Reality (AR) can enable and assist a safe and efficient restart process.  One critical element of a safe restart is to ensure that new requirements for PPE and health screening are properly adhered to prior to an employee entering the workplace. Light Guide can allow employees entering the workplace to check-in safely and without contact, with a standardized process including auto-confirmation that all required PPE is adorned, as well as health screening for fever and other symptoms.  A successful screening event can then be logged to the employee’s badge number for safe entry into the workplace.  The new video on our video page demonstrates how this Light Guide enabled safe-entry screening process can work. Check out the new video with this link.  We are doing our part to #StopTheSpread, and help to keep our customers safe as they restart and return to work with Light Guide.

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