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REACHING INDUSTRY 5.0 THROUGH ADVANCED ANALYTICS

January 20, 2023
By Nick Van Damme Director of Products, TrendMinder

Most operational experts are already on a digitalization journey, yet plans are
in the works for the next factory of the future. Those just beginning a digital
transformation start by automating the factory floor. They then go through a
series of phases as they increase their level of digital and analytics maturity.
But, once companies reach the end of their initial journeys, where do they go?

The answer is Industry 5.0. An extension of Industry 4.0, this leg of the
journey adds human intelligence to automated systems. Operational experts who
use advanced analytics to make data-driven decisions will find they are well on
their way toward the factory of the future.


ESTABLISHING A FOUNDATION ON A DIGITALIZATION JOURNEY

In short, the goal of Industry 5.0 is to pair human intelligence with artificial
intelligence (AI) so the combined system can achieve levels of operational
excellence not possible for either on their own. Rather than a new journey, the
extension of the Fourth Industrial Revolution demonstrates a change toward
innovative technology, such as advanced analytics, the industrial internet of
things (IIoT), AI, and machine learning (ML).

Industry 5.0 is a concept that improves communication and collaboration between
humans and their artificial counterparts. During Industry 4.0, companies enable
autonomous decision-making processes, monitor assets and processes in real time,
and enable equally real-time, connected value-creation networks through early
involvement of stakeholders. The extension of the ongoing digital transformation
seeks the same optimization goal as its predecessor but requires the skill of
operational experts to make more accurate decisions.

For example, an automated system might suggest an action that an operational
expert knows is not in the best interest of production. The expert’s reasoning
skills are necessary to prevent a mistake. Operational experts also can adjust
automated processes so that errors are less common.

Merging human and artificial intelligence does not happen instantaneously. It
becomes part of the overall digital transformation. Companies just starting
their journeys begin a series of phases for improvement and growth. Reaching a
new phase represents an increasing analytics maturity level.

Process manufacturing companies also follow a similar path in their journeys.

 * Automated Phase — In an automated factory, sensors report information back to
   a database known as a historian. Companies realize small improvements,
   particularly around safety.
   
   
 * Data-Driven Phase — As factories start using advanced analytics to find
   hidden clues in their operational data, they enter the data-driven factory
   phase.
   
   
 * Connected Phase — When all the data is connected, it is democratized
   throughout the organization. Operational experts can compare time-series data
   with contextual data from other business systems during the connected factory
   phase.
   
   
 * Augmented Phase — The highest level of Industry 4.0 is the augmented factory.
   Here, companies begin to add ML techniques and manage by exception.

Reaching the augmented factory is a great achievement for process improvement
but closing gaps between human intelligence and AI is necessary before a company
can go further. A hybrid model, where people work alongside their smart systems,
is the preferred approach.



As organizations progress along digitalization, they must overcome challenges
before moving to the next phase and growing their digital and analytics maturity
level. As the analytics maturity increases, business value also rises.



FOCUSING ON THE OPERATIONAL EXPERT

A data-driven factory has embraced advanced analytics software to provide
operational experts with information to optimize their manufacturing processes.
In the past, engineers did not have direct access to an analysis of process
behavior. They relied on the expertise of a data scientist. This created
friction, as data scientists use a language heavy in math and statistics.

Today, companies still use data scientists for the 2-3 percent most critical
assets and to deploy algorithms inside advanced analytics software. However,
advanced analytics empower operational experts to resolve about 80 percent of
their daily questions for themselves. Adding contextual data, such as
maintenance records or shift reports, gives them a more holistic view of process
behavior.

Operational experts can make better decisions with direct access to key
performance indicators. The advanced analytics software helps put resources at
their fingertips to improve process behavior and increase overall efficiency.
They also help a company accelerate the achievement of its sustainability goals.

For the most complex cases and to set up soft sensors, data scientists can apply
machine learning techniques using an integrated Python notebooks hub within the
advanced analytics software. With notebooks, data science and engineering teams
can reduce roadblocks to communication and collaborate on even more
opportunities for operational improvement.

Although Industry 4.0 focuses on technology, AI was never meant to replace
people. Instead, it was meant to provide operational experts with better
information to make more informed decisions. As operational experts begin to
automate tasks and apply machine learning techniques, they also can decrease
repetition, create anomaly detection models, and get prescriptive
recommendations to take corrective actions.


PREPARED FOR WHAT’S NEXT IN THE JOURNEY

Advanced analytics solutions help operational experts solve most production
challenges themselves while providing a more complete picture of production and
data science projects.

While most manufacturers start their digitalization journeys by automating the
factory floor, by the time they become data driven, they can easily segue into
the next step of realizing the benefits of Industry 5.0.

 * Automation
 * Manufacturing Management
 * Smart Manufacturing


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HEADQUARTERS

1000 Town Center, Suite 1910
Southfield, MI 48075
313.425.3000


CLEVELAND OFFICE (TOOLING U-SME)

3615 Superior Avenue, East Building 44, 5th Floor
Cleveland, OH 44114
866.706.8665


TORONTO OFFICE

7100 Woodbine Avenue, Suite 312
Markham, ON L3R 5J2
888.322.7333


SME-RELATED WEBSITES

SME Education Foundation SME Media SME Connect Tooling U-SME Store SME Blog

SME EVENT WEBSITES

AeroDef Manufacturing Canadian Manufacturing Technology Show (CMTS) EASTEC
FABTECH FABTECH Canada FABTECH Mexico HOUSTEX Montreal Manufacturing Technology
Show (MMTS) North American Manufacturing Research Conference (NAMRC) RAPID + TCT
Smart Manufacturing Experience SOUTHTEC WESTEC Western Manufacturing Technology
Show (WMTS)
© 2024 SME. All rights reserved.
Terms of Use SME Privacy Policy SME Governance SME Careers