Sep 02, 2025

In today’s highly competitive manufacturing environment, success is no longer defined by simply keeping machines running. The modern factory must be agile, data-driven, and optimized at every level in order to succeed. That’s where the connected factory comes in. A truly connected factory is a smart, technology-driven ecosystem where people, machines, and systems work in harmony to drive real-time decisions, optimize outputs, and accelerate productivity.

Heartland is proud to partner with Zebra Technologies to lead this transformation. In a recent webinar, Zebra’s Enrique Herrera, Principal of Manufacturing Solutions, and Heartland’s Alan Thompson dove into the key concepts, challenges, and solutions driving the connected factory movement. Whether you’re just starting your digital journey or optimizing a mature facility, this blog explores how you can use connected technologies to modernize operations, empower your workforce, and boost bottom-line results.

Check out the webinar here.

What Is a Connected Factory?

The term "connected factory" isn’t new, but it is evolving rapidly. Early definitions focused on basic connectivity and visibility across operations. Today, a connected factory means far more; it’s a fully integrated manufacturing ecosystem that enables real-time tracking, digital collaboration, predictive insights, and automated quality control.

At its core, the connected factory focuses on three pillars:

• Actionable Visibility – Real-time tracking of materials, assets, and workflows, not just within a plant, but across the broader supply chain.
  
  
• Augmented Workforce – Empowering frontline workers with mobile devices, task tracking, and intelligent assistance tools that simplify complex jobs
  
  
• Optimized Quality – Leveraging automation, machine vision, and traceability solutions to ensure consistency, reduce rework, and meet compliance standards.

The connected factory initiative builds on these pillars to deliver scalable, end-to-end solutions. Through their hardware, software, and partner ecosystem, Zebra and Heartland help manufacturers achieve visibility, efficiency, and control at every step of production.

Common Challenges in Manufacturing Modernization 

Despite rising interest in digital transformation, many manufacturers face persistent roadblocks on the path to modernization. According to Zebra’s Vision Study (an in-depth survey of over 1,200 global manufacturing leaders) four key challenges consistently stand out:

1. Disjointed Tech Environments
   Many factories operate with a patchwork of legacy systems, hardware solutions, and manual workflows. These environments are difficult to integrate, making visibility and coordination a constant struggle.
   
   
2. IT and OT Convergence
   Bridging the gap between Information Technology (IT) and Operational Technology (OT) is essential, but difficult. IT and OT teams often have different priorities, toolsets, and timelines, as well as limited bandwidth, which can slow down transformation.
   
   
3. Long ROI Cycles
   Foundational investments in infrastructure, like network upgrades and automation platforms, often have long payback periods. Gaining executive buy-in and budget allocation requires clear roadmaps and scalable use cases.
   
   
4. Workforce Challenges
   New technologies require new skills. As manufacturers onboard new workers and upskill existing ones, intuitive, user-friendly tools are critical to minimizing disruption and training time.

Heartland specializes in helping manufacturers navigate these challenges with tailored solutions that meet each company’s level of readiness, from first-time automation to advanced machine vision.

What Actionable Visibility Really Looks Like

Operational visibility is the lifeblood of a connected factory. It is no longer enough to know that an order is in process. You need to know where that order is, which components are still required, and where those components are located on the floor.

Using technologies like RFID, real-time location systems (RTLS), and mobile computing, Zebra and Heartland help factories track:

• Work-in-progress (WIP) as it moves through production
• Material consumption and replenishment needs
• Asset location and utilization
• Personnel movement

While ERP systems can track orders digitally, real-time physical tracking of components and subassemblies help frontline workers avoid bottlenecks, eliminate time spent searching for parts, and can significantly improve productivity.

Empowering the Augmented Workforce 

In many manufacturing environments, frontline workers are juggling paper-based processes, outdated terminals, and limited real-time support. The result? Wasted time, errors, and employee frustration.

The augmented workforce focuses on giving operators the right tools to do their jobs faster and smarter. These technologies include: 

• Mobile Computers and Wearables – Providing immediate access to critical data, work instructions, scanning capabilities, and system updates anywhere on the manufacturing floor.
  
  
• Voice-Directed Workflows – Streamlining complex tasks by allowing workers to operate hands-free and eyes-up. Voice solutions also enhance safety and improve accuracy.
  
  
• AI-Powered Assistance – Equipping frontline employees with intelligent guidance based on real-time conditions and historical data.

Instead of sifting through training manuals or chasing down supervisors, workers can ask a question and receive immediate guidance, right from their mobile device or voice-powered hardware. This shift toward self-service speeds up onboarding and helps retain a new generation of tech-savvy workers.

Optimizing Quality Assurance with Vision and Traceability

Product quality isn’t just about avoiding defects – it’s about maintaining brand trust, meeting regulatory requirements, and minimizing costly chargebacks. Traditional quality checks often rely on manual inspections and spreadsheets, but in a connected factory, quality control is embedded directly into the production process.

Heartland’s quality assurance technologies include:

• Barcode Solutions – Provide reliable identification of raw materials, WIP goods, and finished goods. Barcode solutions also enable rapid traceability, inspection checkpoints and real-time logging.
  
  
• Machine Vision Systems – Automated cameras that inspect products, measure tolerances, and flag defects in real time.
  
  
• RFID Solutions – High volume reading and process enforcement ensuring that QA steps are completed quickly, and in order.
  
  
• Mobile Computing – Empowering real-time QA and data access while workers move between workstations, departments, warehouses and docks.
  
  
• Traceability Tools – Tracks components, batches, and operators throughout production, enabling full root-cause analysis when problems arise.

Scalable Solutions that Grow with Your Business

No two factories are the same. Some are still operating with clipboards and spreadsheets, while others are experimenting with AI and robotics. Heartland and Zebra meet customers where they are, offering a tiered approach to modernization that considers your unique needs.

This journey doesn’t require ripping out existing infrastructure. Heartland helps clients modernize step-by-step, using system integration tools to upgrade vs. replace interfaces, layer in automation, and enable intelligent workflows, even on legacy platforms.

Ready to Get Connected?

Heartland is here to help you take the next step toward a smarter, more connected factory. So, whether you need to upgrade mobile devices, improve tracking and traceability, or explore machine vision and AI, our experts can guide you every step of the way. Schedule a consultation today.

Explore the Vision Study

Want deeper insights? Listen to our webinar replay and get free access to Zebra’s Connected Factory Vision Study to discover global trends, benchmarks, and technology adoption strategies from manufacturers just like you.