A new approach with Industry 5.0: Developing a human-centered automation strategy – Image: Xpert.Digital
The challenges of Industry 4.0: Why SMEs are often skeptical
The industrial landscape is in a state of constant flux. About a decade and a half ago, the fourth industrial revolution began, known as Industry 4.0, a collective term for a multitude of digitalization solutions and data-driven production systems. The goal was to increase efficiency and productivity through the use of cutting-edge technology. However, despite the promising approaches, many small and medium-sized enterprises (SMEs) remain skeptical of this concept. Standardized solutions often appear too complex, costly to implement and operate, or seem more focused on what is technically feasible than on actual needs. This frequently leads to employees feeling overwhelmed rather than receiving support.
A new approach with Industry 5.0
However, it is becoming clear that there are alternative ways to harmoniously unite technology and people. This is where Industry 5.0 comes into play, an approach that puts people back at the center. Instead of focusing solely on technological innovations, the aim is to foster symbiotic collaboration between humans and machines. One example of this is a project by the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) in cooperation with Mitras Composites Systems GmbH. Together, they have developed a semi-automated assembly scenario for the construction of bicycle garages, enabling robust, economically sustainable, and, above all, human-centered processes. This was based on a comprehensive needs and requirements analysis conducted in close cooperation with employees.
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Development of a human-centered automation strategy
The project revealed the need to replace previously manual assembly tasks with a hybrid automation solution. The goal was to increase productivity and relieve employees of physically demanding tasks. By integrating robots and automated systems, employees can now utilize their skills in more value-added activities. In these hybrid scenarios, humans and technology work hand in hand to efficiently complete tasks. This allows employees of all ages and genders to be employed in assembly, as heavy lifting and handling tasks are facilitated by automated support.
When transitioning from manual to semi-automated processes, it is crucial that the solutions are designed with a human-centered approach. Simply introducing technology is insufficient; it must be adapted to the needs and abilities of the employees. Therefore, a cognitive task analysis was conducted in the Fraunhofer IWU project. This involved closely observing the assembly processes and conducting interviews with employees from various departments. This approach ensured that the employees who would later work with the automated systems were the focus from the outset. The insights gained helped to understand the requirements for automation solutions and to identify potential improvements directly within the process.
Stefan Ott, Managing Director of Mitras Composites Systems GmbH, emphasized the added value of this customized approach. Often, there are no perfectly tailored solutions available on the market. The collaboration with Fraunhofer IWU enabled the company to specifically assess which areas could be meaningfully automated and what impact this would have on employees. This ensured that the implemented solutions benefited both the company and its employees.
Values-based development of industrial production
Industry 5.0 goes beyond the purely technological perspective of Industry 4.0. It is a value-based evolution that recognizes people as a crucial factor. The realization is that a technology-driven transformation of production systems alone is insufficient to achieve the desired efficiency gains, especially for smaller production runs. Furthermore, traditional manufacturing systems are often not flexible enough to respond to individual customer requirements and fluctuations in demand.
By consistently involving employees in the design of processes and automation solutions, these systems can be developed to provide genuine 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 innovative capacity.
The "Human in Production" department at the Fraunhofer IWU in Chemnitz addresses precisely this point. Through research in the field of cognitive engineering, innovative concepts for automation processes are being developed, making technology more human-centered and creating hybrid solutions. The team led by Dr. habil. Franziska Bocklisch consistently aligns Industry 4.0 technologies with the values of sustainability, resilience, and human-centeredness. The focus is always on concrete, industry-ready, and transferable solutions that increase productivity and efficiency while simultaneously ensuring stable value chains.
The advantages of human-centered approaches
Regardless of which automation options companies ultimately choose, human-centered approaches open up numerous new possibilities. By systematically capturing knowledge and skills, internal know-how is formalized and sustainably secured. This knowledge can be digitized and, for example, supports the faster onboarding of new employees. Assistance and operator guidance systems can be used strategically to optimally support employees in their tasks.
Fraunhofer IWU focuses not only on manual tasks but also considers other human cognitive abilities. Decision-making and problem-solving processes are crucial in areas such as preventive maintenance, quality assurance, and fault diagnosis. By incorporating these aspects, companies can not only optimize their processes but also specifically promote the skills of their employees.
Dr. Franziska Bocklisch emphasizes the importance of close collaboration with companies and customers for human-centered research and development. Only through joint exchange can needs and requirements be precisely identified, solutions developed, and potential consequences assessed. This cooperative approach differs significantly from traditional automation strategies, which often considered the degree of automation as the sole measure of efficiency.
The future of production: symbiosis of man and machine
The efficient production of the future will not be determined solely by technology, but by the optimal combination of human knowledge and technical capabilities. The targeted use of human skills in conjunction with high-performance human-technology systems will become increasingly crucial for sustainable and more resilient production. Companies that pursue this approach are better positioned to react flexibly to market changes and to withstand external disruptions.
The symbiotic collaboration between humans and machines leads to workplaces that are not only more efficient but also more attractive. Employees feel valued and involved, which leads to higher motivation and satisfaction. This is particularly advantageous for medium-sized companies, as it allows them to increase their competitiveness while simultaneously creating a positive work environment.
Human-centered industry as the key to success
Industry 5.0 demonstrates that people must be at the heart of technological innovation to achieve long-term success. Integrating employees into the development and implementation of automation solutions creates processes that are both efficient and flexible. Companies benefit from increased productivity, while employees benefit from more ergonomic working conditions and recognition of their skills.
The collaboration between Fraunhofer IWU and Mitras Composites Systems GmbH demonstrates how such approaches can be implemented in practice. Sustainable improvements can be achieved through customized solutions 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 embark on this path will not only benefit economically, but will also make an important contribution to a sustainable and humane working environment.
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