Adopting Industry 4.0, Awaiting Industry 5.0

There is a world of new possibilities emerging in manufacturing, from innovations in machinery, robotics, automation, IoT devices, big data, analytics and artificial intelligence. This is the world of the fourth industrial revolution – Industry 4.0 – and manufacturing professionals want to ensure their organizations are ready to take advantage of these technologies, and to grow with them toward the next revolution … Industry 5.0.

But there are challenges along with the opportunities of transitioning to a more digital and interconnected future.  How did we get to Industry 4.0? And what lies ahead? Let’s look back before looking ahead.

–  Industry 1.0 was the first industrial revolution, between 1750-1900, when machinery powered by powered by coal and steam transformed production processes and transportation of manufactured goods.

–  Industry 2.0 followed, with the advent of electrical technology leading to mass production techniques, improving cost efficiency.

–  Industry 3.0 began in the 1970s with the emergence of computer controls, and the start of the digital revolution. Automated computers required human programmers, and manufacturers used programmable logic controllers and in-circuit test electronics, and these developments helped further progress in automation.

Meanwhile, the growth of global supply chains spread Industry 3.0 benefits, keeping it operative today and influencing the creation of Industry 4.0.

–  Industry 4.0 is flourishing in the 2020s as the digital and physical worlds become increasingly interdependent. Manufacturing has been transformed by innovations like drones, smart machines, IoT devices, robotics, and cloud and edge computing – and advances in automation mean that machines and devices increasingly operate independently, enhancing human decision-making with timely insights that boost efficiency and productivity.

–  Industry 5.0 is an idea that manufacturing analysts are starting to define, with a focus on machine-human collaboration that will promote greater precision and safety, and further efficiency. When automated machines and computers manage repetitive tasks and take on dangerous work, they free up people to work on more complicated tasks. We can anticipate wider use of tools like digital twins, enriched IoT-derived modeling, machine learning, and generative AI.

Crucial factors in Industry 4.0

Manufacturers today are increasingly aware of the importance of sustainability, to conserve resources as well as to produce more efficiently. In Industry 4.0, IoT devices allow real-time monitoring of interconnected systems, like tracking delivery vehicles or checking the temperature of factory equipment that may be mis-calibrated or about to fail.

Because so much data is exchanged between computers and IoT devices, enhanced cybersecurity has gained significance in Industry 4.0. Without strong protections, an organization’s IoT data is at risk of disruption or exploitation. However, IoT data collection can feed models without directly interfacing with plant networks or equipment controls. By using encrypted cellular transmissions, dedicated IoT networks and cloud enrichment, manufacturers can mitigate security risks, and secure critical systems and data.

One result Industry 4.0 progress is manufacturers’ enhanced ability to harness predictive maintenance (PdM). Sensors in IoT devices send data to computers that analyze the information in real time to help managers and operators determine if a component or system is about to fail. By using a non-network connected cellular model, PdM data can be processed “at the edge” and enriched in the cloud, mitigating cybersecurity risks. Through secure APIs, insights are pushed back to production maintenance systems, allowing for timely execution of work without compromising network security.

Rather than reacting quickly to issues, machine-health monitoring applications use a continuous data stream to identify potential failure modes up to 12 weeks in advance. This predictive insight allows for organized planning and scheduling of maintenance tasks without disrupting production. By guiding adjustments or preventative actions, potential failures can often be avoided entirely. The integration of IoT devices enables industrial maintenance teams to provide proactive equipment maintenance so that processes run smoothly and efficiently.

The result is manufacturing enterprises becoming more efficient, with less downtime due to offline equipment. Rolls-Royce installed IoT sensors in aircraft engines, which help to predict when to perform maintenance. Data from these sensors also helps Rolls-Royce improve the performance of its engines.

Transportation and logistics improve under Industry 4.0 with new opportunities for smart logistics. DHL employs IoT sensors to monitor shipments, optimize delivery time and constantly improve how it routes shipments in real time.

Cloud and edge computing are the foundation of Industry 4.0, enabling manufacturers to integrate vast amounts of data, models, and systems. Unlike previous models that relied on local or on-premises machine-health monitoring, today’s cloud-based infrastructure allows manufacturers to analyze data in real time and connect people across locations.

The cloud’s scalability supports advanced analytics like machine learning and artificial intelligence, making it easier to detect patterns, predict equipment failures and enable condition-based maintenance. Using cloud and edge computing, manufacturers can process data efficiently, make informed decisions, and improve operational efficiency.

With so much more accessible data, Industry 4.0 merges the physical and digital dimension of manufacturing, with virtual reality (VR) and augmented reality (AR) systems replacing the need for physical documentation, printed manuals, or intranet searches. These technologies allow workers to access the exact information they need in real time, directly through the AR or VR display, whether they are training, designing or operating complex equipment. With cloud connectivity, AR and VR not only provide the necessary data but can also bring remote support personnel directly to the point of need, enhancing efficiency and problem solving.

Transforming processes in Industry 5.0

Industry 5.0 will further integrate tools such as AI, robotics, and automation into manufacturing processes. As the work of manufacturing becomes increasingly automated, Industry 5.0 will bring humans into the decision-making process as workers collaborate with robots. As machines handle dull, repetitive, and dangerous tasks, people are free to exercise their creative roles and bring more value to the design and manufacturing processes.

Collaborative robots will feature prominently in Industry 5.0. And additive manufacturing will accelerate the availability of customized production. While some jobs previously reserved for humans will be done by automated machinery, a management development firm forecasts that industrial automation will generate 97 million new jobs in 26 countries by 2025. Accordingly, manufacturers need to increase their investment in employee training and education to take embrace three pillars of Industry 5.0:

–  First is a human-centric approach, with people still intimately involved in making decisions, defining their job processes and influencing how processes function.

–  The second pillar is resilience, or the ability of Industry 5.0 enterprises to quickly adjust their focus in response to changes in the marketplace. AI and machine learning will help manufacturers respond rapidly during turbulence in their industry.

–  Sustainability is the third pillar of Industry 5.0, driving corporate social responsibility initiatives that impact the manufacturing bottom line. By focusing on actions that reduce manufacturing costs and improve the efficient consumption of natural resources, companies can boost operational efficiency while aligning with broader social and environmental goals. Sustainability-focused efforts contribute to better resource management, lower waste, and enhanced energy use, which then support a more human-centric and efficient manufacturing process.

Exploring Industry 4.0 and 5.0

The capabilities of AI coupled with the latest developments in robotics and automation are advancing, and new iterations are becoming more powerful and useful for humans working in manufacturing. When you factor in innovations such as IoT devices to gather information and monitor and interconnect your equipment, it becomes easier to optimize large, complicated processes in designers’ studios and on the factory floor.

Micah Statler is Director of Industrial Technologies at Advanced Technology Services, responsible for the strategy, execution, and delivery of technology-driven maintenance solutions.