Why Operator Knowledge Still Matters in the Age of AI: Insights from Windak Inc.’s Plant Manager

February 2, 2026

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With insights from Madis Tomson, Plant Manager, Windak Inc., USA

Automation and digital tools have made cable packaging systems smarter than ever. While intuitive HMIs and smarter diagnostics play a key role, operator knowledge continues to be one of the biggest factors influencing uptime, product quality, and production stability.

Madis Tomson, Plant Manager at Windak Inc., builds on experience gained since 2011 in the EMEA region, where he developed deep expertise in production challenges and operator performance, and now supports cable manufacturers across North and South America.

What follows is a candid, practical look at why operator training still plays a defining role — even in the era of AI.

His answers reveal a truth many manufacturers recognize but rarely articulate: operators need more than instructions; they need understanding of how the machine functions and how it should operate.

Q1: If automation is becoming smarter, why is operator training still so important?

Today’s automation makes machines feel simpler to run, but underneath that simplicity are servo-driven systems, coordinated motion control, calibration routines, and safety logic — all of which rely on operators and engineers making correct decisions.

Madis explains:

“Behind the screen there is increasing complexity. Operation and setup tasks are often separated: operators may find daily running easier, but process engineers and maintenance teams require deeper knowledge.”

Even with AI and digital assistance, cable packaging machines still requires human intervention, especially when conditions change or when troubleshooting is needed.

According to Madis:

“AI cannot fully capture the thought process of the engineers who design the machine. There’s always a handover needed from creator to user.”

That’s why Windak’s training goes far beyond “press Start and monitor the line.”

Today’s automation is also becoming far more precise, predictable, and repeatable, especially at very high speeds.
And that’s exactly why operator training is more important now, not less.
It ensures customers understand the cause-and-effect behind every action, giving them the knowledge to prevent issues before they impact production.

Q2: What kind of mistakes do operators typically make — and why do they matter?

Small mistakes often create the biggest problems.
They may seem minor in the moment, but the impact accumulates quickly.

Madis highlights the most common ones:

“Mistakes like choosing the wrong recipe, misfeeding cable, or skipping calibration can lead to wasted material, downtime, and inconsistent coil or spool quality.

A machine from 15 years ago would tolerate a slightly wrong setting — you’d lose a few meters and restart. Today’s equipment runs 2–3× faster and with much tighter tolerances. One small mistake can scrap an entire high-value spool or trigger a safety sequence that takes hours to reset.”

These issues are almost never caused by a lack of effort, but by a lack of understanding of how the machine reacts to each step.

Madis adds:

“When operators don’t understand why a step is important, they are more likely to improvise. That’s where problems start.”

Proper training removes improvisation and replaces it with consistency.

Q3: Has the need for training changed over the years?

Yes — significantly.
Equipment is faster, control systems are more advanced, and production demands are higher. Because of this, training has become more structured and more tailored.

Madis explains how Windak adapted:

“We apply the Kaizen principle of continuous improvement to our training just like we do to our machines. Over the years, we’ve gathered customer feedback and shaped the training accordingly.”

He continues:

“Some customers want to train a core team. Others want to rotate entire shifts through the sessions. We adapt to both — whatever leads to consistent performance.”

Training is no longer a one-size-fits-all add-on; it has become a critical part of the long-term success of the line, not just for operators, but for the broader support team as well.

Q4: What does Windak’s training actually focus on?

Windak’s training covers everything from basic operation to advanced troubleshooting.

According to Madis:

“Our program covers the full spectrum — from basic operation to understanding how the machine works.”

This includes:

inspecting that spools, stretch wrap material, labels etc. are correct for the selected recipe and of good quality
identifying early warning signs
understanding recipe logic
avoiding tension and feeding issues
proper calibration routines
consistent setup between shifts
safe operation and shutdown

Madis explains the core purpose:

“If production results fall short, trained teams can identify where the deviation comes from — setup, operation, or maintenance.

Today’s systems are so precise and fast that only deep understanding keeps them running at 98–99% OEE — instead of dropping to 70% the moment something unexpected happens.”

This knowledge protects manufacturers from inconsistent performance and unnecessary downtime..

Q5: What benefits do manufacturers see after proper operator training?

According to customer feedback gathered across North and South America, the gains are clear and immediate.

Madis summarizes the impact:

“Training gives operators confidence. Confident operators make fewer mistakes, work safer, and help maintain consistent output.”

Conclusion: Even in the Age of AI, Operators Define the Results

Automation continues to evolve, and AI will play a larger role in manufacturing.
But the foundation of consistent, efficient cable packaging remains the same: knowledgeable, well-trained operators who understand both the interface and the system behind it and can decide correctly at 2 a.m. on a Friday shift.

Windak’s training approach — shaped by real production cases and years of hands-on field experience — gives manufacturers the confidence that their team can run equipment safely, efficiently, and with consistent results across every shift.

Let’s make sure your team is ready. Contact Windak to discuss the training format that best supports your operation.