Bridging futuristic gap: From Industry 4.0 to human-centric era of Industry 5.0

The industrial sector is facing a paradigm shift. Industry 4.0 may have been able to demonstrate to the world the use of automation, data transfer, and the Internet of Things (IoT) to its fullest potential.

However, we are currently poised to enter a completely new era of industrial development. Industry 5.0 is more of a transformation phenomenon than an upgrade, where human-centric, resilient, and sustainable development of the industry is targeted. A leap to achieve the same is required.

HMI design for collaborative environments
In the age of Industry 4.0, everything was more automation-oriented and sometimes the human aspect was overshadowed by automation efficiency. This is reversed in the age of Industry 5.0, which places greater value and priority on human involvement. This is most clearly demonstrated in the design of the HMIs.

The objective has shifted from merely running a machine to encouraging cooperation between humans and intelligent systems throughout the entire production process, from the shop floor to post-production work. The new-generation HMIs should be characterized by:

• Intuitive and Natural: Interfaces should veer away from the mundane entries and towards more natural interactions, using ergonomics.
• AI Driven: AI can help interfaces adapt and better respond to human requirements.
• Safety-First: It is necessary to incorporate safety systems into collaborative environments where humans and robotic systems can cohabitate without endangering each other.

Embedding eco-friendly principles in industrial innovation
Sustainability is not an afterthought in Industry 5.0; it is a core pillar. Bridging the gap involves tightly coupling industrial innovation with eco-friendly principles, moving towards a circular economy. The guiding philosophy here is the "Three Rs": Reduce, Reuse, and Recycle.

True industrial innovation now means scrutinizing every aspect of the product lifecycle:
• Material Sourcing: Utilizing green materials and assessing the carbon footprint from the very beginning.
• Energy Efficiency: Reimagining manufacturing processes to minimize energy consumption.
• Waste Management: Developing ecosystems to efficiently dispose of or repurpose byproducts.

Despite these goals, challenges remain, particularly in global supply chains. Often, a product designed in one region is manufactured in another, making the efficient disposal or recycling of byproducts a complex logistical hurdle. Success in Industry 5.0 requires addressing these adjacent processes with the same priority as the production line itself.

Immersive visualization for workforce empowerment and skilling
The most exciting frontier in Industry 5.0 is the application of immersive technologies, that is, AR, VR, and Digital Twins, for empowering the workforce. While these are all technologies that have been existed for many years, their deep integration into PLM is truly the defining feature of this shift.

Digital Twins and Predictive Power: Other than mere 2D or 3D replicas, immersive digital twins allow for real-time simulations. This allows industries to anticipate challenges with a high degree of accuracy, enabling effective predictive maintenance that improves productivity while reducing downtime.

AR/VR in Training and Skill Development: There are sectors, such as automotive or semiconductor manufacturing, in which equipment is too expensive to be taken out of production in order to conduct training. AR and VR provide a solution by:
• Cost Mitigation: Providing high-fidelity virtual mockups of expensive machinery for training without sacrificing productivity overall.
• Improving Adaptability: Immersive training provides a far greater return of adaptability and retention compared to traditional classroom settings.
• Address Workforce Churn: Providing continuous, scalable skilling for workforces that may experience high turnover.

Verification and After-Sales: Immersive tech also quickens development. By employing quality rendering of CAD data, designers can verify models early in the stage of development, thus saving considerable time and cost even before a physical prototype is made. In addition, after-sales, AR aids technicians in performing real-time MRO tasks and, in most instances, allows for paperless and technology-assisted servicing.

Looking ahead: 2026 horizon
As we look toward 2026, the key trend that is going to be at the forefront is the integration of AI-powered immersive technologies. This convergence is unlocking value across the entire industrial lifecycle, from conceptualization and production to post-production and promotion.

The future of Industry 5.0 is all about the seamless integration of technology, where the insights and interactions of AI technology come together in perfect harmony, ensuring that technological progress serves humanity. We are certainly in the nascent stages of this evolution, but the motto is shifting from slow and steady to full speed.

-- Maulik B Raval, Practice Head, VXR, Tata Elxsi.