How AI is Closing the Skills Gap and Building a Resilient Workforce

Jan. 23, 2025
The ongoing industrial labor shortage threatens productivity and competitiveness, but it’s also an opportunity for change. Here’s how the latest digital technologies, powered by explainable AI to share operations expertise, are beginning to address the workforce challenge.

By 2030, it’s estimated that critical industrial sectors, including oil and gas, chemicals and general manufacturing, could face 2.1 million unfilled jobs. This gap stems from the retirement of experienced workers and the increasing complexity of industrial operations.

One of the most exciting developments related to closing this gap is how AI is reshaping workforce development. Technologies like AI-powered digital advisors are helping to level the playing field, providing expert guidance to workers with less experience and enabling them to make decisions that once required decades of expertise. 

Use of these new AI technologies elevates expertise and leads industrial companies down a path to assuring every day is their best day of production and every worker is a world-leading expert. In effect, industrial companies can now provide their decades of institutional knowledge to all operational and maintenance staff that need to diagnose a problem or carry out a best practice. 

Imagine a maintenance technician, just a few years into their career, confidently diagnosing a machine issue with help from an AI agent that includes a reference to the service records and a recommended set of step-by-step actions that have been used to resolve similar issues.

That’s why adoption of this technology isn’t about replacing people — it’s about giving the existing workforce access to enterprise knowledge so they can perform their tasks safely and with expert efficiency. At Honeywell, we call this Digital Cognition.

Explainable AI (XAI) resolves the mystery of how AI decisions are made

Unlike traditional AI models that operate behind the scenes in a “black box,” the Digital Cognition concept emphasizes the use of Explainable AI (XAI), which provides a reference and explanation as to how the recommendation was made. With this background, recommendations become trusted, easy to understand and based on historical precedent. 

Learn more about explainable AI. 

Imagine a maintenance technician, just a few years into their career, confidently diagnosing a machine issue by describing symptoms and receiving a response from an AI agent that has searched the enterprise maintenance service records to identify a potential root cause. The response includes a reference to the service records and a recommended set of step-by-step actions that have been used to resolve similar issues.   

To do this, Digital Cognition leverages decades of enterprise knowledge and makes the information universally accessible. And with each new action, the enterprise knowledge base becomes even more comprehensive. That’s how Digital Cognition not only empowers the workforce to perform more efficiently, it also expands enterprise knowledge and capabilities in real time.

How XAI builds industrial resilience 

The industrial skills gap isn’t just a workforce problem — it’s an operational risk for businesses. According to market research firm IDC, some labor-intensive industries lose 20% to 30% of revenues every year due to inefficiencies. This is where AI can prove invaluable, by helping organizations work smarter, faster and safer.

Take Honeywell’s Field PKS (Process Knowledge System) system as an example of how the Digital Cognition concept can be applied in real world industrial activities. By analyzing historical service records, Field PKS guides workers in solving complex issues that would otherwise require an expert. The issues Field PKS can address range from a board operator making the best decision based on a pattern of alarms to a maintenance technician identifying the root cause of a rotating asset that is cavitating and making a noise. It’s like having the world’s best expert accompany every employee 24/7, helping less seasoned workers perform at their best. 

The result of having this kind of expert decision-making assistance is faster response times, less downtime and greater efficiency.

The Digital Cognition concept is already beginning to transform how businesses operate. Honeywell’s collaborations with industry leaders like Chevron and Qualcomm demonstrate this:

  • With Chevron, we are working to enable operators to infuse AI into Honeywell's Experion distributed control system (DCS) as part of a co-innovation project centered on AI-enabled operational guidance to better inform control room decisions. Together, Chevron and Honeywell are working to develop a new generation of AI-assisted alarm management solutions that will help operators make decisions to increase the efficiency, safety and reliability of process operations and industrial assets. The new solutions will include an Alarm Guidance application that provides operators with guided and specific actions to effectively respond to alarms and operational events, helping to reduce lost profit opportunities and process safety incidents. Using AI technology, the system will mine historical data on past actions to identify patterns of alarms and the corresponding operator actions that successfully return the process to normal operation.

  • At Qualcomm, Honeywell is incorporating Qualcomm Technologies' connectivity and AI capabilities into the Honeywell Field PKS. By integrating these capabilities, Honeywell's Field PKS will be able to help provide connectivity to remote manufacturing facilities for greater data capture and analytics at the edge. A key aspect of this partnership focuses on combining Qualcomm's low-power, AI-enabled processors with native wireless connectivity, software and computer vision with Honeywell's sensing technologies to develop a family of industrial sensors for monitoring process parameters, asset parameters and environmental conditions. 

These partnerships highlight how these AI-driven solutions are not only practical but transformative for industry.

The AI-powered workforce of the future

The future industrial workforce will look very different from today’s. Thanks to the power of AI to create a new level of cognition, employees will spend less time troubleshooting and more time solving meaningful problems. They’ll gain expertise faster, work more safely and adapt to new challenges with confidence.

For businesses, the stakes are clear. Those that adopt AI now will lead in operational efficiency, employee retention and market relevance. The divide between those who embrace these changes and those who hesitate will only grow wider. AI isn’t just a tool; it’s a competitive edge and a key to long-term success.

The time to act is now. AI is the bridge between today’s challenges and tomorrow’s opportunities. By embracing these tools and partnerships, industries can close the skills gap, build resilience and create a workforce ready to tackle whatever comes next.

Jason Urso is chief technology officer and vice president of Honeywell Industrial Automation.

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