Manufacturing in the Era of Industry 5.0

Summary

The Industry 5.0 revolution is unlike any manufacturing revolution before. We aren’t waiting for a single technological breakthrough such as the steam engine, the assembly line, the computer. The evolution of Industry 5.0 signifies a huge industrial shift towards humans; it’s even been described as a human-centric complement to Industry 4.0.

When we consider both Industry 4.0 and Industry 5.0, it is the frontline workers on the manufacturing floor which will experience the biggest impacts. While automation and optimization have been introduced by the integration of IoT, there are more complex roles and responsibilities to fill for a smaller pool of frontline workers. There’s a growing skills gap, highlighting how the in the evolution of manufacturing, Industry 5.0 is a development that is both crucial and overdue.

As a result, the need for a digitally-connected worker approach is greater than ever before.
 

Connected workforces are the beating heart of Industry 5.0

This connected human-centric approach will not only empower workers and address the evolving skills and training needs of employees, but it will also increase the competitiveness of industry and help attract the best talents.

For the new workforce generation, it’s 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 A more fulfilling job experience that crushes the outdated negative perceptions of manufacturing work.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, by driving new efficiencies and innovations. We must move on from manufacturing work that was once deemed dull, dangerous and dirty, to a shop floor that promotes continual learning, development and collaboration.

This is already having repercussions in manufacturing, where there is not just a skills shortage but a definite labor shortage by making these sorts of jobs ‘cool’ for Gen Z, many of whom are disillusioned with further education and are looking for a rewarding and enjoyable lifestyle.
 

Say hello to the connected worker approach

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, there is still a need to empower workers and facilitate better cohesion on the shop floor to promote increased productivity, efficiency and safety. Enter the connected worker approach.

The connected worker approach holds 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 seamlessly interface 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 continues to evolve, building a connected frontline workforce is crucial in bridging the gap between traditional shop floor processes and the digital future. Connected workers are the linchpins of smart factories, driving continuous improvement and operational excellence through their ability to blend human ingenuity with technological efficiency.

In the great digital rush, don’t forget the humans keeping operations running smoothly!

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 must still 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 evolving skills and training needs of employees, 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 key manufacturing metrics such as safety, productivity and quality. For instance, Poka customer Bosch has reported an 8% productivity gain from implementing connected worker technologies.

Skilled workers promote safety, productivity and retention

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 also crucial.

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.
 

Building resilience where it matters most

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.
 

Humans and technology: Combining two to work as one

There’s no doubt that humans will continue to be the backbone of manufacturing organizations. Without them, manufacturers lose creativity, versatility and key decision-making. The connected worker approach is about helping humans and technologies such as Industry 4.0 work together. The perfect harmony of human ingenuity and machine efficiency will be the lynchpin for competitive differentiation.

As Poka co-founder Alex Leclerc has often said, “Any competitor can buy the same equipment and raw materials as you. What gives you a competitive edge is your people and your know-how.” Humans have always been, and will continue to be, crucial in manufacturing. Industry 5.0 represents a welcome shift forward to valuing human contributions amidst the rise of digital transformation.