Manufacturers have long relied on paper-based systems to track production, perform quality checks, or document standard operating procedures (SOPs). But in today’s fast-paced data-driven world, these paper documents are holding many facilities back. Moving to a paper-on-glass approach, where printed documents are replaced with interactive, digital interfaces, is a fairly simple yet powerful, way to unlock new efficiency, accuracy, and compliance across operations.

At its core, a paper-on-glass strategy means the checklists, work instructions, and batch records operators once carried on clipboards are made available on tablets, HMIs, or kiosks within the facility. But the impact of using a paper-on-glass approach goes far beyond convenience. This shift lays the foundation for smarter, faster, and more connected manufacturing. Let’s explore some of the many benefits implementing a paper-on-glass strategy could bring to your facility.

Real-Time Visibility and Fewer Errors

When instructions and forms are digital instead of manual, updates can be rolled out instantly, ensuring operators always have access to the latest documentation or SOPs. Interactive forms can be designed to guide users through each step, reducing training time and eliminating errors caused by outdated paperwork or illegible handwriting. Built-in validation prompts, links to help content, and automated data capture can also be included to further improve accuracy.

Additionally, because information is logged in real time, supervisors have instant visibility into production progress, compliance data, and quality results. This means faster, data-informed decisions can be made and fewer surprises are likely during audits or reviews.

Smarter Compliance and Easier Audits

For heavily regulated industries such as pharmaceuticals or food and beverage, accurate and accessible documentation is essential. A paper-on-glass strategy provides traceable, revision-controlled records that can include electronic signatures, user logs, and timestamps. Auditors can search digital records in seconds instead of digging through binders. And when deviations occur, it’s easier to pinpoint root causes using timestamped digital logs linked to process historian data.

Knowledge Retention and Workforce Readiness

As experienced operators retire, critical operational knowledge often leaves with them. Digitizing SOPs formalizes information that may only live in someone’s head. In addition to ensuring consistent execution and preserving institutional know-how for the next generation, standardized digital work instructions allow new team members to be trained more quickly.

Sustainability and Cost Savings

Reducing paper waste isn’t just good for the environment, it’s also good for the bottom line. By eliminating the printing, distribution, and storage costs associated with paper documentation, manufacturers can save thousands of pages (and dollars) annually while aligning with corporate sustainability goals.

Getting Started with Your Paper-on-Glass Strategy

In general, the most successful paper-on-glass strategies start small. We recommend identifying your high-impact processes that include repetitive manual entry, such as batch records, maintenance logs, or shift handoff forms, to start with. These processes will provide quick wins that demonstrate measurable value and build momentum for broader rollout.

It’s also equally important to involve your people early. Operators, technicians, and supervisors should help shape digital workflows so they’re intuitive and effective. Also, be sure to work with your IT and OT teams closely on tasks such as device connectivity, data security, and integration with systems like your manufacturing execution system (MES) or enterprise resource planning (ERP) system.

Paper-On-Glass: A Foundation for the Future

Paper-on-glass isn’t just about getting rid of paper; it’s about creating a bridge to true digital transformation. By capturing real-time, structured data and automating manual workflows, manufacturers can position themselves to advance toward more resilient, agile operations.

Learn more about the variety of control system modernization services we offer.