A new approach with Industry 5.0: Development of a human-centered automation strategy - Image: Xpert.Digital
The challenges of Industry 4.0: Why SMEs are often skeptical
The industrial landscape is in constant change. The fourth industrial revolution began about a decade and a half ago, known as Industry 4.0, which is a collective term for a variety of digitalization solutions and data-driven production systems. The aim was to increase efficiency and productivity by using the latest technology. But despite the promising approaches, many small and medium-sized companies (SMEs) are skeptical about this concept. Standardized solutions often seem too complex, cost-intensive to implement and operate, or appear to be more oriented toward what is technically feasible than toward actual needs. This often leads to employees being overwhelmed instead of receiving support.
A new approach with Industry 5.0
However, it turns out that there are alternative ways to harmoniously combine technology and people. This is where Industry 5.0 comes into play, an approach that puts people back at the center. Instead of focusing exclusively on technological innovations, it is about promoting symbiotic collaboration between humans and machines. An example of this is a project by the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in collaboration with Mitras Composites Systems GmbH. Together they have developed a partially automated assembly scenario for the construction of bicycle garages that enables robust, economically sustainable and, above all, human-centered processes. The basis was a comprehensive needs and requirements analysis, which was carried out in close cooperation with the employees.
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Developing a human-centered automation strategy
As part of the project, it became clear that the assembly activities that had previously been carried out manually should be replaced by a hybrid automation solution. The aim of this was to increase productivity and relieve employees of physically demanding tasks. By integrating robots and automated systems, employees can now use their skills in more value-adding activities. In these hybrid scenarios, people and technology work hand in hand to efficiently complete work tasks. This makes it possible for employees to be employed in assembly regardless of age or gender, as heavy lifting and handling tasks are made easier through automated support.
When switching from manual to partially automated processes, it is crucial that the solutions are designed to be human-centered. It is not enough to simply introduce technology; it must be adapted to the needs and abilities of the employees. A cognitive task analysis was therefore carried out in the Fraunhofer IWU project. The assembly processes were closely observed and discussions were held with employees from various areas. This approach ensured that the focus from the start was on the employees who would later work with the automated systems. The insights gained helped to understand requirements for automation solutions and identify potential directly in the process.
Stefan Ott, Managing Director of Mitras Composites Systems GmbH, emphasized the added value of this individual approach. There are often no tailor-made solutions available on the market. The collaboration with Fraunhofer IWU enabled the company to specifically assess which areas could be sensibly automated and what effects this has on employees. This ensured that the solutions introduced benefit both the company and its employees.
Value-based further development of industrial production
Industry 5.0 goes beyond the purely technological perspective of Industry 4.0. It is a value-based development that recognizes people as a decisive factor. The finding is that a technology-driven conversion of production systems alone is not enough to achieve the desired efficiency gains, especially for smaller quantities. In addition, traditional manufacturing systems are often not flexible enough to respond to individual customer requests and fluctuations in demand.
By consistently involving employees in the design of processes and automation solutions, these systems can be developed in such a way that they provide real support in everyday work. Employees who contribute their skills and experience not only work more productively, but also identify more strongly with their workplace. They are more motivated, use digital solutions more consciously and actively contribute to the company's ability to innovate.
The “People in Production” department at the Fraunhofer IWU in Chemnitz addresses exactly this point. Research in the field of cognitive engineering creates innovative concepts for automation processes that make technology more human-centered and create hybrid solutions. The team around Dr. habil. Franziska Bocklisch consistently aligns Industry 4.0 technologies with the values of sustainability, resilience and people-centeredness. The focus is always on concrete, industrially suitable and transferable solutions that increase productivity and efficiency while at the same time securing stable value chains.
The benefits of human-centered approaches
Regardless of which automation variants companies ultimately choose, human-centered approaches open up numerous new possibilities. Through the structured recording of knowledge and skills, internal know-how is formalized and sustainably secured. This knowledge can be digitized and supports, for example, the faster training of new employees. Assistance and worker guidance systems can be used specifically to optimally support employees in their tasks.
The Fraunhofer IWU not only focuses on manual activities, but also takes other cognitive abilities of humans into account. Decision-making and problem-solving processes are of great importance in preventive maintenance, quality assurance and error diagnosis. By integrating these aspects, companies can not only optimize their processes, but also specifically promote the competence of their employees.
Dr. Franziska Bocklisch emphasizes the importance of close collaboration with companies and customers for human-centered research and development. Only through mutual exchange can needs and requirements be precisely identified, solutions developed and possible consequences assessed. This collaborative approach differs significantly from traditional automation strategies, where the level of automation was often viewed as the sole measure of efficiency.
The future of production: symbiosis of man and machine
The efficient production of the future will not only be determined by technology, but by the optimal combination of human knowledge and technical possibilities. The targeted use of human skills in conjunction with powerful human-technology systems is becoming increasingly crucial for sustainable and more resilient production. Companies that follow this approach are better positioned to respond flexibly to changes in the market and to assert themselves in the face of external disruptions.
The symbiotic collaboration between humans and machines leads to jobs that are not only more efficient, but also more attractive. Employees feel valued and included, which leads to higher motivation and satisfaction. This is particularly advantageous for medium-sized companies as it allows them to increase their competitiveness and at the same time create a positive working environment.
Human-centered industry as the key to success
Industry 5.0 shows that people must be at the center of technological innovation in order to be successful in the long term. By integrating employees into the development and implementation of automation solutions, processes are created that are both efficient and flexible. Companies benefit from increased productivity, while employees benefit from more ergonomic working conditions and the appreciation of their skills.
The collaboration between Fraunhofer IWU and Mitras Composites Systems GmbH illustrates how such approaches can be implemented in practice. Sustainable improvements can be achieved through tailor-made solutions that are tailored to the actual needs of the company and its employees.
The future of industry lies in the harmonious combination of human expertise and technological innovation. Companies that take this path will not only benefit economically, but will also make an important contribution to a sustainable and humane working world.
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