Is manufacturing really moving on from Industry 4.0? With so much promise of technology, efficiency and advanced automation, what is it that Industry 4.0 wasn’t able to deliver? Turns out that what was removed from operations is exactly what Industry 5.0 has identified as essential for progress: The human element, resilience, and sustainability.
It’s not enough to simply have processes to produce products. Nor is it adequate to tick the boxes for ESG and Health and Safety. Technology will remain an essential part of manufacturing, but how it’ll be applied will be very different.
It was thought that robotics, automation and monitoring production through IoT devices would deliver greater levels of efficiency and worker safety. Reports show that despite this, 80% of workers experienced some form of work-related injury.
It’s the unexpected that’s throwing a spanner in the works. Disrupted supply chains due to global events and unpredictable actions that lead to accidents. Technology can carry out what it’s been programmed to do, but it lacks the human intuition needed to navigate uncertainty.
This is where Industry 5.0 steps up.
Industry 5.0 is designed to work with humans, leveraging their knowledge and understanding of situations and providing specific support in areas where they need it. An example at the edge of innovation is a robotic exoskeleton that workers wear to help them manage heavy loads and reduce the risk of injury.
A simpler example would be a manufacturer looking to reduce its energy usage. To do this it needs to know what processes are drawing power when, in order to optimise energy efficiency. This could be done through IoT devices. The data fed is then into an AI monitoring system that looks to identify patterns and areas for improvement.
At the same time there are often opportunities to use the by products from one process, such as heat or steam, to support another process. This is where the human element comes in. A broader view of operations and industry experience helps to identify more innovative ways to become energy efficient. Simply put, humans use the data provided by technology to connect the dots.
By creating more closed loop systems, manufacturers not only reduce their operational costs, they also become more sustainable and resilient. This in turn reduces reliance on external providers and reduces the risks that come with economic shocks or extreme climate events that are now becoming the norm rather than the exception.
Waste management is another area where technology and humans working together can create efficiencies, cost savings, and even generate new revenue streams. In a circular economy, which is the gold standard for sustainability, waste is a resource that has value. Therefore, sustainability is not just about finding ways to reduce waste, but also finding other uses for resources that would previously have been discarded.
The applications of technology in manufacturing move beyond automation and robotics with Industry 5.0. AI-supported decision making and optimization, virtual or augmented reality, 3D printing and digital twins make manufacturing one of the most innovative sectors to be working in. The advancements and optimizations are just the beginning as manufacturing enters a new model for operating.
