The packaging industry's workforce problem isn't about headcount. It's about skill compression. Executives say the answer lies in making machines easier to run, not necessarily more automated.
According to PMMI's From Complexity to Capability white paper, 57% of summit participants identified people, (performance and progress) as the most actionable topic discussed, well ahead of future-proofing operations (17%), stronger together (15%), and scaling smart (12%).
The reason: plants can no longer assume deep tenure, stable technical depth, or one-language teams.
This shift is reshaping what a high-performing asset looks like. Equipment must be easier to understand, easier to reset, easier to troubleshoot, and easier to train against. Plants must also rely less on undocumented tribal knowledge.
When asked which technology solutions are most likely to improve workforce productivity, respondents pointed to simple, frontline-ready tools over abstract AI adoption. Simplified operations via QR codes, tablets, and augmented reality tied for the top spot at 47%, alongside automation of repetitive tasks. Simplified operations and lower complexity followed at 38%, with prescriptive data—"tell me what to do" tools—at 31%.
Notably, more advanced concepts like HMI simplification (19%) and AI use-case development tools (10%) ranked far lower, signaling that leaders want technology that meets operators where they are.
Participants say that AI should serve as a wrapper around good documentation, not a substitute for it. If SOPs, one-point lessons, manuals, and maintenance plans aren't already usable, AI will only expose that weakness faster.
Timing matters too. Participants described separating installation and training responsibilities during startup, and exposing operators to new technology before or during Factory Acceptance Tests so the learning curve begins earlier.
One participant referenced what they called a "golden hour" for post-installation training—the period after operators have worked the line and experienced real problems firsthand.
The takeaway for CPGs and OEMs is that usability and reliability are now linked. The moment of truth isn't when a line passes acceptance, it's a month later, when a less-experienced operator sees a recurring fault on the second shift. Reusable training assets, remote expert access, visual guidance, and embedded troubleshooting serve both workforce enablement and OEE improvement.
SOURCE: 2026 From Complexity to Capability: Integrating Systems, People, and Partnerships for Future-Ready Packaging Operations
For more insights from PMMI's Business Intelligence team, find reports, including From Complexity to Capability, Building an AI Advantage in Packaging Equipment, and Trends and Challenges in Pharmaceutical Manufacturing at https://www.pmmi.org/business-intelligence.
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