Industry 5.0: Human-Centric Industry 4.0

This article appeared in the Sep/Oct issue of MiMfg Magazine. Read the full issue and find past issues online.

Discussions about advancing automation and employing an array of other Industry 4.0 solutions have been trending for years but the movement has gained steam with the introduction of higher-level artificial intelligence tools. Still, there is one thing that most people agree on: computers cannot replace people.

In fact, Ryan Pohl of Praeco Skills refers to what’s happening in our current times as the “Fifth Industrial Revolution,” or Human-Centric Industry 4.0.

Technology offers manufacturers an abundance of solutions for streamlining, simplifying and increasing the speed of communications and processes, particularly those that are redundant, physically demanding or that require 24/7 attention. And that frees humans to focus on managing the machines or using their skills in other areas of a business — as there are many things that robots cannot do just yet.

Human-Centric Industry 4.0

As a talent development resource for middle- to high-skilled manufacturing jobs and a solutions partner for MMA members, Praeco Skills is supporting businesses as they integrate technology while bringing people along to ensure they are not stifling engagement. A key to doing so is to involve all stakeholders, especially those on the front lines, Pohl says.

“It cannot be a top-down approach. It’s a full team approach,” he says. “There’s a lingering, old-school mentality out there that engineering is going to determine the best way to handle these things and dictate it to the shop floor. I’m just not seeing that jive very well anymore, especially with these new technologies.”

In fact, Pohl says that companies should start by learning about these capabilities collaboratively as a team.

“I’m saying management, engineering, supervisors, operators all in the same room, all in the same class, learning about technologies available through Industry 4.0 and how they, as an organization, can implement them,” he says. “The more the shop floor is involved in new technology implementation, the greater the usage of new technology, the higher the return on investment.”

Pohl adds that integrating people’s skills with technology implementation is essential for success.

“I fear that people think that AI is going to provide the complete solution to the continuing talent shortage in the manufacturing industry, but it’s just not going to happen,” he says. “AI is just a tool. It’s a phenomenal tool, but it’s not going to solve the talent shortage. If we’re expecting AI to do things that only humans can do, then we’re going to be woefully disappointed.”

Pohl notes that there’s already an “Industry 5.0” concept, particularly used in other countries, that says that we will lose all the benefits of Industry 4.0 if we don’t figure out how to integrate humans into it.

“Industry 5.0 is starting to gain a tremendous amount of traction,” he says. “We’re already seeing the fear and disengagement happen in our workforce because, as people lean on 4.0 technologies, humans are asking, ‘Where does that leave us?’”

Pohl says he has interacted with hundreds of shop workers over the past 25 years who are concerned that they will be forced to take direction from an AI-driven algorithm.

“If they think that, they don’t know what I do,” he says. “Humans are still the bosses here. Technology isn’t going to take us over.”

“You have to have human experts who are driving the integration,” Pohl adds. “I don’t think you have to be afraid of AI because it just can’t do what humans can do. Computers can’t replace humans. I’ll argue that all day.”

Enhancing Efficiency through Artificial Intelligence

At the same time, advancements in automation offer revolutionizing benefits for businesses, although business owners agree that the human factor remains integral to success.

Fowlerville-based Total Security Solutions (TSS), which engineers, manufactures and designs bulletproof barrier systems, has implemented many forms of automation that have helped the business meet customer demands with greater efficiency and precision.

CEO Jim Richards says that as they are facing what other manufacturers are facing in terms of the labor shortage, employing technological solutions has been helpful.

“Our customer count is growing faster than our employee count,” he says. “Technology has helped us become more efficient at what we’re doing. We’re still adding people and we’re still growing, but it’s allowed us to keep up with our customer demand.”

Richards says some of the AI and other automated resources that they have or are considering implementing to enhance efficiencies at TSS include:

Using AI capabilities and other technological tools to collect and analyze data, which allows the business to be more predictive in decision-making.

• Upgrading their ERP system to optimize, streamline and enhance sales.
• Using AI for customer service and support, including a phone system that recognizes “trigger” words, knows where to route calls and can evaluate the quality of communications for future budgeting and training purposes.
• The use of autonomous carts to help move materials from one cell to another, allowing the human handlers to remain at one station instead of constantly moving around the plant from one station to another.
• Leveraging ChatGPT during the hiring process in an effort to identify the most ideal candidates for a particular position.
• Capturing installation reports in real time, allowing the customers to receive updates as soon as the jobs are completed.

Paul LaVigne, Chief Marketing Officer for TSS, adds that they consider AI as a way to elevate their customers’ experiences and assist their employees, whose ability to think creatively and independently is indispensable.

“We’re looking at how to apply AI as a tool to help people, not replace them,” he says. “A computer hallucinates, but that is not imagination and innovation.”

Gauging the Feasibility of Automation Integration

For a company like P&THE Manufacturing (PTM), a holding company that invests in manufacturing companies, making a small but educated investment into AI tools has been a great way to start small with the hope of scaling later. In fact, PTM CEO Pancho Hall says they’ve quickly realized the benefits of advanced automation tools based on an initial investment.

Fruitport-based TCI Aluminum, owned by PTM, has recently installed an aluminum stack melting system and is enhancing it with BYTEDGE, a platform that uses “digital twins” with machine learning and AI for predicting product and component failures.

Hall, whose company serves as a problem solver to manufacturers who have unique challenges, says many nonprofit organizations and state-funded agencies are available for small businesses that are looking to enhance their capabilities through automation solutions.

“I’m not sure that Industry 4.0 will fit every size company now,” he says. “If the math makes sense, there are generally people who can help you. Sometimes the math doesn’t make sense today, but you can maybe work on a plan-of-action until the math does make sense.”

Richards says there are many AI and automation capabilities on the market but businesses should ask themselves if a tool indeed relieves a pain point or if it’s just another gadget.

“I believe AI is in its infancy stage and that people who understand it, embrace it and don’t get caught chasing after every shiny object are going to move ahead quicker,” he says, noting that AI can be especially helpful for small businesses looking to scale but lack the manpower to do so. “I don’t think the workforce shortages and skilled labor shortages are going to go away anytime soon, so those companies that are investing in automation and AI are going to be the ones who will be able to scale and grow their businesses.”

Industry 4.0 certainly continues to grow, so much so that it has taken on a new life with the Industry 5.0 concept. While automation provides helpful solutions for manufacturers, integrating it with human intuition and creativity will be essential moving forward.

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