Industry 5.0: Evolution or Revolution?

To set the stage for understanding 5.0, it’s essential to reflect on the major advancements in industrial revolutions that have shaped our world today. Each step has brought about significant changes in technology, society, the economy, and influence in how industries function.

Industry 1.0 (Late 18th to Early 19th Century): Often referred to as the First Industrial Revolution, this marked the transition from the agriculture-based economies that existed before the industrial revolution, to the advent of industrialized societies. The introduction of machines powered by water and steam transformed industries, particularly textiles and manufacturing. Innovations such as the “spinning jenny” (textiles), steam engine (various industries), and power loom (textiles) not only increased the capacity of the production process, but also reduced reliance on manual labor. The steam engine also ushered in major changes in transportation. These shifts led to the establishment of factories, drawing workers from rural areas into urban centers, and fundamentally altering social structures and labor market trends.

Industry 2.0 (Late 19th Century): The next industrial revolution, sometimes called the Technological Revolution, saw the advent of electricity and mass production techniques, including the assembly line, being used in the meatpacking and textile industries. While credited with the advancement of the assembly line, Henry Ford did not begin using this technique until the early 20th century. These techniques developed in the late 19th century enabled companies to produce goods on a scale never seen before. Expanding railroads and telegraphs also facilitated faster communication and transportation, further integrating markets and stimulating economic growth.

Industry 3.0 (Late 20th Century): The third industrial revolution began in the 1960s and continued through the 1980s, so late 20th-century timeframe. The advent of computers and automation characterized the Third Industrial Revolution. This period marked a significant shift as businesses began to adopt information technology in their business operations. Robotics, computer-aided design (CAD), programmable logic controllers (PLCs), and the personal computer (PC) transformed production lines and process manufacturing industries and society as a whole, enhancing efficiency, capacity, consistency, and more. Data collection and analysis became an integral part of decision-making processes, allowing companies to improve their operations based on real-time information and decisions. This era also saw the significant continuation of globalization, with companies leveraging technology to expand their reach into international markets easily.

Industry 4.0 (Very Late 20th Century to Present Day): Often described as the era of connectivity because it has been characterized by the rapid advancement of digital technologies, Industry 4.0 integrates computational elements with physical processes, the Industrial Internet of Things (IIoT), the continued evolution of personal mobile communications, and big data analytics, all of which are revolutionizing manufacturing processes. Smart factories are now the gold standard of process manufacturing, where machines, devices, and systems communicate with each other to optimize production in real-time. This connectivity level allows for unprecedented efficiency and adaptability improvements, enabling manufacturers to react swiftly to changing consumer and market demands. Technologies such as artificial intelligence (AI), cloud computing, and advanced robotics play a crucial role.

With this historical context, it makes sense that we see 5.0 emerge as a natural step from the previous industrial revolution eras, addressing the challenges and opportunities left by its predecessors. Each industrial revolution should build on the previous, creating a continuous flow of innovation rather than isolated events.

Think about it: Industry 4.0 is providing us with incredible advancements in automation, as well as data management and analytics, delivering an era of smart factories where sensors and machines work together in a system of production. But with all that technological marvel, we also see some significant challenges—job displacement, lack of a skilled workforce, significant cybersecurity concerns, and an increasing awareness of our environmental footprint. As companies wrestle with these issues, it has become clear that innovations had to address not just productivity, but also the people behind the processes and the planet we all inhabit. 5.0 aims to bridge this gap by integrating the advanced technologies of 4.0 with a focus on the experience in the workplace by the company personnel. Technology should enhance our capabilities, not replace them.

Imagine factories where robots and humans work side by side, each contributing their strengths to create something. This people-focused approach marks a new shift from the previous eras, which often prioritized production and process efficiency over the well-being of workers.

Industrial sustainability plays a pivotal role in shaping this evolving industrial landscape. With climate change and environmental degradation being of increasing interest to society, industries are increasingly asked to or required to adopt practices that balance their profitability with environmental responsibility. This isn’t just a passing trend; it’s been a shift in mindset developing for decades. In this light, 5.0 isn’t just about the latest technology; it’s about ensuring that innovation lines up with the ethical responsibilities society has begun to say that manufacturing has to our planet and future generations.

As we look forward, its proponents say that 5.0 represents more than just a new label; it’s an opportunity for businesses to learn from the past. It challenges process manufacturers to rethink approaches and adapt to a world where societal values are front and center. The future isn’t just about what technology can do; it’s about how we can use that technology to enhance our lives, foster creativity, and build a sustainable future.

Supporters of 5.0 argue that the components they purport as 5.0 signify a shift in how industries operate, mainly due to its focus on practices designed with workers in mind, and sustainability. Here are the highlights:

Human-Machine Collaboration: One of the primary and standout features of 5.0 is purported to be its emphasis on collaboration between humans and machines. Rather than replacing human workers, advanced technologies are designed to complement their skills. A potential example is the replacement of manual ingredient batching with semi-automatic operator-involved batching stations. This collaboration is said to boost productivity and is believed to usher in a more creative workforce.

Sustainability Matters: Advocates of 5.0 argue that emphasizing sustainable practices and corporate responsibility is evidence of its status as a revolutionary step forward. As consumers increasingly prioritize environmental consciousness, manufacturers are compelled to adopt environmentally friendly practices and demonstrate accountability. This shift aligns with society’s growing expectations for transparency and sustainability in manufacturing and corporate operations.

Scalable Customization: With the advent of AI and advanced analytics, 5.0 offers the ability for manufacturers to personalize products and services. This ability to adjust offerings to individual consumer preferences marks a significant shift from the approach that one-size-fits-all. A saying from the early 20th century is what Henry Ford is purported to have said about car color; “Any customer can have a car painted any color that he wants so long as it is black”.

Emerging Technologies Integration: Proponents of 5.0 believe that it fully utilizes emerging technologies like AI, blockchain, and advanced robotics in ways that Industry 4.0 did not, and that this integration will lead to improved productivity and quality, as well as reduced costs across the board.

Despite some enthusiasm surrounding the 5.0 definition and purported components, there’s a significant contingent of critics who argue that it is merely the continued results of and an extension of 4.0; that 5.0 lacks the true groundbreaking significance that its proponents claim, and like the previous Industrial Revolution steps had. Here are several points that explain this position:

Evolution, Not Revolution: Critics assert that the changes being included as 5.0 are simply the natural progression and results from that which was established in Industry 4.0. For example, the integration of workers with automation is not a new concept; it has been a leading focus and point of industrial changes for decades. Throughout the 20th century as process controls and automation advanced, manufacturers have sought to find the best balance between worker “gut” intuition and machine operational efficiency, a process that has evolved steadily rather than erupting into a new awareness, shift, or paradigm. The discussion surrounding human-machine collaboration in 5.0 echoes discussions that began many years ago, making it far less of a revolutionary leap, and more of an incremental continuing change.

Marketing Speak and Buzzwords: Many view the term “Industry 5.0” as a marketing strategy rather than an indication of real industrial innovation. In an age where technological advancements are rapidly changing, the creation of new labels can mask real progress. By coining a new phrase/term, proponents of 5.0 risk diluting the meaningfulness of the advancements continuing to be made in Industry 4.0. This can lead to confusion, as many people may struggle to distinguish between genuine innovation and what is just a
rebranding of existing technological innovation as it is implemented, and results are realized.

Complexity Without Clear Benefits: The push for closer collaboration between humans and machines could introduce additional complexity into production processes. While proponents suggest that this integration will lead to greater efficiency, critics argue that industries may struggle to implement these changes effectively. For example, training employees to work alongside advanced robotics requires time and resources, which may not yield immediate returns. If businesses are unable to navigate this complexity, they may face inefficiencies that could hinder productivity rather than enhance it.

Distraction from Core Issues: The buzz surrounding 5.0 may divert attention from more pressing industry challenges, such as labor practices, employee training, and infrastructure improvements. Critical foundational issues might get overlooked by framing the conversation around a new paradigm. For instance, the ongoing need for upskilling workers to adapt to automated environments remains a significant concern. While focusing on the concept of 5.0, stakeholders might neglect to address these essential areas, potentially stalling genuine progress.

Technological Dependence: One key concern about 5.0 is the continued increasing reliance on digital systems, which introduces potential vulnerabilities. As industries become more interconnected, the risk of cyberattacks escalates, potentially disrupting production, compromising sensitive data, and affecting entire supply chains. While the continued search for technological innovation and collaboration is undeniable, it sometimes overlooks essential safeguards that are needed to protect against threats. This imbalance could leave industries underprepared for future cyber risks, raising questions about the long-term suitability of heavy dependence on technology and digital systems.

Impact on Employment: Proponents of 5.0 argue that human-machine collaboration will create new job opportunities, but critics are concerned that automation may lead to job losses instead. As machines become more capable of handling repetitive tasks, roles that rely on manual labor could be phased out in favor of automation. This shift might result in significant job displacement, potentially deepening existing inequalities in the workforce.

Rather than promoting collaboration, the reality of 5.0 could inadvertently create a divide between technological advancements and workforce stability, leaving some segments of the population behind. What do those workers who are suited to and desire manual labor do next? Not all are suited to retraining for higher skill-level positions, and there may not be enough of those new jobs to go around. The impact on individuals and families could be more significant than thought.

Industrial Sustainability Concerns: Although advocates of 5.0 emphasize sustainability, there are valid concerns about the environmental impact of increased technological integration. The production and disposal of high-tech equipment contribute to e-waste, and the energy consumption of smart factories may sometimes offset the sustainability benefits they aim to provide. Essentially, the pursuit of new technologies under the label of 5.0 could unintentionally result in practices that contradict the sustainability goals it sets out to achieve. These challenges require careful consideration to avoid unintended negative outcomes.

So, where does that leave us? As we explore the various viewpoints on 5.0, it’s evident that while the arguments for this 5.0 as a next step in the industrial revolution are compelling; offering a vision of a sustainable, worker-centered future; the concept may be more of a marketing tactic and gimmick than a true industrial revolution. The themes of collaboration, sustainability, and personalization promoted by 5.0 aren’t new; they’ve been a significant part of the innovation conversation since the advent of 4.0.

This doesn’t diminish their importance, however, but it’s important to recognize how much is built on previous advancements. As manufacturing industries continue to adapt, we need to bear in mind that progress often will be built on top of the foundations laid by those that came before us.

Rather than viewing 5.0 as a daring new frontier, it seems more realistic to see it as a continuation of the overall journey in the industrial revolution. This perspective helps us appreciate how each phase (1.0, 2.0, 3.0, and 4.0) shapes our current tools and practices.

It’s essential for everyone to critically evaluate what this new term 5.0 really signifies. Are we genuinely innovating, or simply rebranding existing ideas? By asking these questions, we can ensure that our focus remains on meaningful and innovative improvements, rather than getting lost in the “buzz”.

The future is unpredictable. However, innovation continues to produce advanced technologies like Industry 4.0 that promise to take the manufacturing process to another higher level.  And this is a necessity. But let’s not get lost in marketing buzzwords. Rather, closely understand and evaluate innovation.

With over 50 years of expertise in custom engineering process control and automation systems, automated ingredient batching systems, material weighing, liquid handling, and other bulk material handling solutions for a wide range of process industries, Sterling Systems & Controls proudly has the experience to provide you with expert guidance to achieve your automation and process improvement goals. Contact us today to discuss how our knowledge and expertise can align with your goals and how you can continue your journey toward manufacturing excellence!