Three-quarters of frontline manufacturing workers are comfortable using AI-powered tools, but most still rely on decades-old two-way radios to communicate on the job, according to a new survey from Weavix.
The Weavix 2025 State of Frontline Communications survey found 74 per cent of workers are comfortable with AI-powered tools in the workplace, and 87 per cent are comfortable with technology systems collecting work data for safety and efficiency purposes. However, 67 per cent still use outdated two-way radios as their primary communication method.
The survey polled 300 frontline manufacturing workers across U.S. facilities in November 2025. Respondents represented diverse roles and facility sizes ranging from under 50 to over 1,000 employees across automotive, food processing, electronics, chemical and other manufacturing sectors.
Productivity losses tied to communication gaps
The survey found 53 per cent of manufacturing workers lose at least five per cent of their workday—roughly 24 minutes per shift—waiting for safety-critical information or approvals. Of those experiencing idle time, 63 per cent said it affects their ability to meet production targets.
Applied across the 12.7 million U.S. manufacturing workforce, this represents $15.4 billion in direct annual productivity loss at current median wage rates, according to Weavix. This figure does not account for secondary costs such as quality defects or safety incidents.
“There’s a persistent assumption that frontline workers aren’t ready for advanced technology, but our data proves the opposite,” said Kevin Turpin, CEO and founder of Weavix. “Workers are comfortable with AI and data collection, but their leaders have hamstrung them with prehistoric communication devices or nothing at all, wasting time and creating risks.”
Workers see practical applications for AI
When asked about specific AI applications, 78 per cent of workers said AI-powered real-time language translation between workers who speak different languages would be somewhat to extremely valuable. Additionally, 84 per cent believe technology could help solve communication problems in their workplace.
Among workers who expressed concern about AI adoption, job security was the primary worry at 32 per cent, suggesting hesitation stems from economic anxiety rather than resistance to technology itself.
Smartphone restrictions create trade-offs
The survey found 64 per cent of frontline workers operate under partial or complete smartphone restrictions on the production floor. Manufacturers often implement these policies for safety, security and focus reasons, but the restrictions can remove everyday communication and documentation capabilities when teams need to capture and share information quickly.
Knowledge transfer and feedback challenges
Workers with 20 or more years of experience were the least likely to feel their feedback reaches decision-makers, at 29 per cent, compared with 43 per cent among mid-career workers. As these long-tenured employees approach retirement, companies may be losing both institutional knowledge and their willingness to share it, according to the survey.
Overall, 62 per cent of workers said they have suggested process improvements to management, but only 38 per cent feel their ideas or feedback always reach decision-makers.
Despite communication challenges, 81 per cent of workers reported being more engaged at work than last year, and 94 per cent are optimistic about workplace safety improvements in 2026.
The survey was conducted by Pollfish on behalf of Weavix. Weavix is a frontline engagement and communications company that serves customers across manufacturing, construction and hospitality.
