The Industrial Revolution and the subsequent industrial “revolutions” were characterized by groundbreaking advancements, like the steam engine or computers. Industry 5.0 is breaking the mold. It is not hinged on a particular breakthrough, but on a change in mindset. Industry 5.0 is both a vital, yet overdue phenomenon for the manufacturing industry. This new 5.0 age is set to shake up manufacturing as we know it by embracing the human-centric capabilities of the already existing Industry 4.0 characteristics.
The humans impacted most by Industry 4.0, and the heart of Industry 5.0, are the frontline workers on the manufacturing shop floor. The integration of IoT and Industry 4.0 has advanced automation and optimization, but has also led to more complex roles and responsibilities for fewer frontline workers. This shift has highlighted a growing skills gap, and the need for a more digitally-connected worker approach.
A human approach
This connected, human-centric approach will not only empower workers and address the evolving skills and training needs of employees, but it also will increase the competitiveness of manufacturers and help them attract the most talented workers.
For the new workforce generation, Industry 5.0 is not about replacing humans with robots but about creating a collaborative, productive partnership which includes using smarter devices and may well involve working alongside robots and cobots, to enable workers to collaborate, learn new skills, and share knowledge, with the result that they work smarter, not harder. A more fulfilling job experience that crushes the outdated negative perceptions of manufacturing work.
Taking advantage of this partnership will propel manufacturing into the future economy by driving new efficiencies and innovations. Manufacturers must move on from manufacturing work that was once characterized as dull, dangerous, and dirty, to a shop floor that promotes continual learning, development, and collaboration.
This is having repercussions in manufacturing already, where there is not just a skills shortage but a definite labor shortage; it is making these manufacturing jobs ‘cool’ for Gen Z workers, many of whom are disillusioned with further education and are looking for a rewarding and enjoyable lifestyle.
Technology bridges the gap
Current frontline manufacturing workers say that 71% of their work tasks are still dull, dirty, or dangerous. Despite being in the midst of a new generation of manufacturing, these workers still require empowerment and better cohesion on the shop floor. Those improvements will promote increased productivity, efficiency, and safety.
The connected worker approach is the key to empowering the workforce of the future. Connected workers are equipped with software applications that provide access to the knowledge, skills, and support they need to perform tasks safely and to standard—right on the factory floor.
This class of software applications and tools enables workers to interface seamlessly with equipment, processes, data, and other employees in order to facilitate standard work, enhance communication, and improve operational efficiency from top floor to shop floor.
As manufacturing evolves, building a connected frontline workforce will be crucial to bridging the gap between traditional shop floor processes and the digital future. Connected workers are the linchpin of smart factories, driving continuous improvement and operational excellence through their ability to blend human ingenuity with technological efficiency.
Empowered is productive
Industry 5.0 addresses the broader need to connect and empower the people on the shop floor who operate the machinery.
During the great digital rush, manufacturers still must focus on connecting the human workforce that keeps everything running smoothly. With adequate top-floor support, frontline workers can take on more responsibilities and feel a sense of accountability to “win every shift”, evolving from machine operators to managers of their responsibilities.
However, human-centric approaches and productivity are not mutually exclusive. In fact, Industry 5.0 is bringing them closer together than ever before.
This connected human-centric approach not only empowers workers and addresses the employees’ evolving skills and training needs; it also increases the competitiveness of industry and helps attract sought-after talents.
Evidence shows that well-skilled, engaged, and empowered workers contribute positively to critical manufacturing metrics such as safety, productivity, and quality. For instance, Poka customer Bosch has reported an 8% productivity gain from implementing connected worker technologies.
Foster a culture of learning
The U.S. Bureau of Labor Statistics reported a 37% turnover rate in manufacturing in 2023, driven by physically demanding work, safety concerns, lower wages, and limited workplace flexibility. While raising wages and offering flexible schedules can help, other strategies to empower frontline workers are crucial too.
Fostering an environment of continual learning and training brings huge benefits to both employers and employees. Skilled workers are safer, more productive, and more likely to stay in their organization when offered development opportunities. According to the Manufacturing Institute, 69% of workers under the age of 25 value training opportunities as a key reason for choosing and staying with an employer.
Connected workers benefit from a learning culture that provides access to training materials and skill development directly at the moment and place of need. This reduces reliance on shadowing and accelerates onboarding, making training more effective.
Resilience and versatility are critical
A resilient workforce is one that adapts to change and challenge, while maintaining high levels of engagement and productivity. Given the pace of change within the manufacturing industry, this skill is as important as ever.
Versatility is key to workforce resilience, and ensuring that workers have the skills to adapt to new tasks and technologies is essential. Connected worker platforms with role-specific skills management functionality can help identify training gaps and set priorities.
A supportive workplace culture also contributes to resilience, and a factory where workers are valued and empowered to reskill and upskill fosters a positive working environment from the top floor to the shop floor. Adopting a connected worker approach can enhance this culture by prioritizing autonomy, collaboration, visibility, and transparency.
Unlocking new manufacturing capabilities
Human talent will always be manufacturers’ greatest asset, due to individuals’ creative thinking, adaptability, and skillsets. As Industry 5.0 gains popularity in the manufacturing sector, industry leaders must adopt a connected worker approach to truly harness the competitive edge of combining human talents with technological capabilities.
“Any competitor can buy the same equipment and raw materials as you,” according to Poka co-founder Alex Leclerc. “What gives you a competitive edge is your people and your know-how.” Humans will always be the heart of manufacturing operations, and Industry 5.0 is here to harness that vitality.
Andrea Masterton is vice president of Marketing at Poka, a connected worker app that gives workers the knowledge and tools they need to contribute to manufacturing excellence.
