September 4, 2024
Envisioning a world without the mechanization of labor, mass production of goods, and connected transportation—cornerstones of the First Industrial Revolution—is challenging. Nearly 200 years later, manufacturing has advanced significantly, from 3D-printed homes and collaborative robots (cobots) to augmented reality for job training.
In this article, we cover the pivotal technologies and concepts from both Industry 4.0 and Industry 5.0, and their implications for the future of manufacturing.
What Is Industry 4.0?
Industry 4.0, also known as the Fourth Industrial Revolution, is defined by the emergence of digital industrial technology, notably cyber-physical systems. This evolution has facilitated highly innovative and efficient collaboration between humans and machines, which has in turn enabled the creation of smart, integrated factories and operations. The ultimate goal of Industry 4.0 is to create tailored, versatile manufacturing solutions by leveraging data-driven insights.
Industry 4.0 was first unveiled in 2011, and it has gradually gained traction with manufacturing professionals throughout the decade. Many of Industry 4.0’s cutting-edge technologies work together to create a cohesive manufacturing environment. For example, Internet of Things integration and AI are only made possible through cloud computing. Below are several of Industry 4.0’s key technologies.
Additive Manufacturing (3D Printing)
Additive manufacturing, commonly known as 3D printing, has transformed production processes. It has tremendous benefits that are appealing to employees, company leaders, and organizations as a whole, such as minimized waste, streamlined supply chains, and extended product lifespan. The aerospace industry greatly benefits from this method due to the sector’s rigorous standards and limited production volume.
There are some obstacles to incorporating additive manufacturing into processes. Organizations who do not have individuals with sufficient knowledge and skills in additive manufacturing will struggle to incorporate it. Additional obstacles include the caliber of printed goods and a lack of cross-industry best practices.
Artificial Intelligence (AI)
Artificial intelligence, which includes machine learning, machine vision, and deep learning, has many uses in the manufacturing industry, including conducting quality assurance and sorting packages.
Manufacturers are launching generative AI with some trepidation due to the risk of misleading outputs. Though 70 percent of leaders indicated that they have invested in costly commercial AI models, more affordable open-source solutions may become the trend once their effectiveness is demonstrated.
Big Data & Data Analytics
Big Data organizes the information collected from manufacturers and forms meaningful diagnoses to help enhance operations in a variety of ways, like streamlining warehouse procedures, diagnosing performance issues, and forecasting demand.
Overcoming common roadblocks in data analytics, such as poor accuracy and security, is paramount to using Big Data for decision making.
Internet of Things (IoT)
The Internet of Things employs smart sensors and other gadgets to track things like machine functionality and environmental factors on a minute-by-minute basis.
Universally rolling out smart sensors in manufacturing is complicated by compatibility challenges between older and modern systems, the need for effective staff training and preparation, and data privacy and security considerations.
What Is Industry 5.0?
The Fifth Industrial Revolution, or Industry 5.0, was introduced in 2021 as a set of tools and technologies that build upon Industry 4.0. Industry 5.0 emphasizes using and developing advanced technologies while ensuring that production adheres to the welfare of both workers and our planet. The European Union’s push towards sustainability has been a major driver for Industry 5.0, aligning with global goals like climate neutrality by 2050.
Setting Ethical Guidelines
Ethics come into play in many aspects of the Fifth Industrial Revolution, such as:
- Bias in algorithms: AI and algorithms must be carefully reviewed, monitored, and overseen to mitigate biases.
- Shifting employment landscape: With technological advancements comes a reduced need for traditional roles, such as assembly line jobs. It’s important to train employees in new areas to address the changing needs of organizations.
- Ecological footprint: Organizations should incorporate green materials and sustainable operation strategies, and they should work to move to a circular manufacturing system to cut back on waste.
The global Industry 5.0 market is projected to increase from $65.8 billion in 2024 to $255.7 billion in 2029, reflecting a 31.2 percent compound annual growth rate.
Industry 5.0 in Action
Some of the top companies embracing and furthering the Fifth Industrial Revolution are:
- ABB
In 2023, ABB unveiled an automated flexible miniature circuit breaker (MCB) production line, which uses leading-edge artificial intelligence, automation, and digital methods. The line features seven robots and 16 custom automation devices that boost reliability and effectiveness. - Emerson
Emerson was named the 2024 “Industrial IoT Company of the Year” by IoT Breakthrough—making it Emerson’s sixth time winning this honor. This pioneering corporation is working to help manufacturers reach their environmental objectives through Ovation™ Green, a suite of software and automation solutions. - Honeywell
An important feature of Industry 5.0 is ensuring that workers have the ongoing education they need to work with rapidly advancing technologies. Honeywell advises leveraging virtual reality (VR) and simulation applications for training. - Rockwell Automation
Rockwell Automation seeks to improve human-machine interactions by increasing productivity and worker safety. The enterprise suggests that manufacturers can harness various approaches to advance to Industry 5.0, such as developing AI-native architecture and adopting converged integrated development environments (IDEs).
How to Prepare for Industry 5.0
The Rutgers University online Master of Engineering in Industrial and Systems Engineering prepares students for advancement in the evolving manufacturing industry. The program’s comprehensive curriculum consists of three required core courses and a number of technical elective course options, including in the areas of AI in decision making, engineering management and innovation strategy, and AI-enabled manufacturing.
Effects on Next-Generation Manufacturing
97 percent of industrial manufacturing CEOs indicated that continuing digital and technology transformation to deliver growth and operational advantages is either an important near-term priority.
Industry 4.0 and 5.0 will shape the future of manufacturing, driving expansion and boosting performance with technological advancements like artificial intelligence, digital twins, and machine learning. To elevate their businesses and meet their goals, manufacturers will need to develop organization-wide action plans.
While we don’t know exactly when Industry 6.0 will arrive or what it will entail, experts hypothesize that some machines will reach autonomy by 2050. Other key features may involve extraterrestrial manufacturing and the use of drones or flying factories in the industry.
In the meantime, Industry 5.0 concepts and Industry 4.0 technologies will continue to advance as human roles are redefined. Amidst digital advancements and increasing regulations, manufacturers will need to adopt new approaches to stay competitive, agile, and environmentally conscious.
Shape the Future of Industrial and Systems Engineering at Rutgers University
Unlock your potential with Rutgers’ online Master of Engineering in Industrial and Systems Engineering. You’ll gain cutting-edge skills in data analytics, AI, and optimization, preparing you to lead innovation across industries. With a flexible curriculum taught by industry experts, you’ll be ready to tackle complex challenges and advance your career in today’s data-driven world.
Rutgers School of Engineering is a place of possibilities—for students seeking success, for researchers seeking to create new technologies, and for faculty members and industry leaders seeking to form powerful and productive partnerships.
Rutgers University’s School of Engineering is a vibrant academic community whose richly diverse students and faculty are committed to globally sustainable engineering. Its mission is built on a commitment to fostering the integration of education and research to achieve transformational innovation that is ethically responsible and sustainable.
Download a brochure to learn more, or get started on your application today.