Connected workers, smarter operations: lessons from Danone’s digital transformation journey

In the race to modernise food and beverage manufacturing, digital tools alone won’t deliver transformation. It’s the people — empowered, informed, and connected — who drive real change.

That was the core message from Alessandro Cesare, global digital manufacturing manager at Danone, during his presentation at Smart Manufacturing Food and Beverage Europe in London on 25 September. His session, “Developing a Connected Worker Strategy to Drive Productivity and Enhance Data Collection,” offered a blueprint and key takeaways for manufacturers seeking to elevate frontline teams through technology, culture, and process redesign.

Building the foundations
Before deploying wearables or mobile apps, Cesare emphasised the importance of defining a clear maturity matrix.

“You need to understand where your organisation stands — not just in terms of technology, but in terms of mindset, workflows, and readiness for change,” he explained.

Danone’s approach begins with mapping use cases across different sites and roles. Whether it’s digitising quality checks, enabling real-time maintenance alerts, or streamlining shift handovers, each use case is evaluated for impact, complexity, and scalability. This structured foundation helps avoid fragmented pilots and ensures that connected worker initiatives align with broader operational goals.

Key takeaway for manufacturers: don’t rush into tech deployment. Start by assessing maturity, identifying high-value use cases, and aligning stakeholders around a shared vision.

Streamlining data collection
Food and beverage plants generate vast amounts of data — from temperature logs and cleaning records to downtime reports and packaging line metrics. Yet much of this data remains trapped in paper forms, spreadsheets, or siloed systems.

Cesare highlighted how Danone is standardising data collection across its global network.

“We’re moving from inconsistent, site-specific practices to harmonised digital workflows,” he said. This not only improves data accuracy and audit readiness but also enables cross-site benchmarking and continuous improvement.

By integrating connected worker platforms with MES and ERP systems, Danone ensures that frontline inputs feed directly into enterprise analytics. Operators use tablets or handheld devices to log events, capture photos, and trigger workflows — eliminating manual transcription and reducing errors.

Key takeaway for manufacturers: standardise data capture at the source. Connected workers become real-time contributors to operational intelligence when tools are intuitive and integrated.

Digital transformation
At the heart of Danone’s strategy is a shift from paper-based procedures to digital workflows. This isn’t just about efficiency — it’s about unlocking insights.

“When you digitise work instructions, inspections, and escalation protocols, you create a living system that evolves with your operations,” Cesare noted.

Digital workflows allow for version control, instant updates, and contextual guidance. For example, a sanitation operator can access the latest cleaning checklist, log completion, and flag anomalies — all from a single interface.
Moreover, digital records enable advanced analytics. Danone uses aggregated data to identify bottlenecks, predict equipment failures, and optimise staffing.

“It’s not just about collecting data — it’s about making it actionable,” Cesare said.

Key takeaway for manufacturers: digital workflows are the backbone of connected worker strategies. They drive productivity, ensure compliance, and fuel data-driven decision-making.

Driving adoption
Technology adoption hinges on user experience. Cesare stressed that connected worker tools must be designed for the people who use them — not just for IT teams or data analysts.

Danone invests in training, change management, and feedback loops to ensure that frontline teams feel supported.

“We involve operators early in the design process. Their input shapes the tools, and their engagement drives success,” he said.

Gamification, recognition programs, and peer-led onboarding help build momentum. Sites share success stories, celebrate milestones, and continuously refine their approach.

Key takeaway for manufacturers: adoption is not a checkbox — it’s a journey. Empower workers with intuitive tools, listen to their feedback, and build a culture of continuous improvement.

The road ahead
As Danone scales its connected worker strategy across regions and product categories, Cesare remains focused on impact.

“It’s not about deploying tech for tech’s sake. It’s about making work safer, smarter, and more rewarding,” he concluded.

For food and beverage manufacturers navigating labour shortages, regulatory pressures, and rising consumer expectations, connected workers offer a path forward. By combining digital tools with human insight, companies can unlock new levels of productivity, traceability, and resilience.