Industry 5.0 - The Future of The Industrial Economy (2021)

Industry 5.
0
Industry 5.0
The Future of the Industrial Economy
Uthayan Elangovan
First edition published 2022
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Library of Congress Cataloging‑in‑Publication Data

Names: Elangovan, Uthayan, author.
Title: Industry 5.0 : the future of the industrial economy / Uthayan Elangovan.
Description: First edition. | Boca Raton : CRC Press, 2022. |
Includes bibliographical references and index.
Identifiers: LCCN 2021028869 (print) | LCCN 20210288702 (ebook) |
ISBN 9781032041278 (hardback) | ISBN 9781032041285 (paperback) | ISBN 9781003190677 (ebook)
Subjects: LCSH: Industry 4.0. | Society 5.0. | Automation. | Robots, Industrial. | Human-computer
interaction. | Industrial engineering. | Internet of things–Industrial applications. | Artificial
intelligence–Industrial applications. | Manufacturing industries–Technological innovations.
Classification: LCC T59.6 .E43 2022 (print) |
LCC T59.6 (ebook) | DDC 658.4/0380285574–dc23/eng/20211103
LC record available at https://lccn.loc.gov/2021028869
LC ebook record available at https://lccn.loc.gov/2021028870
ISBN: 978-1-032-04127-8 (hbk)

ISBN: 978-1-032-04128-5 (pbk)
ISBN: 978-1-003-19067-7 (ebk)
DOI: 10.1201/9781003190677
Typeset in Times
by codeMantra
Dedication
To my parents, Elangovan Rajakani and Kanmani

Elangovan, who educated me on the qualities of self-control
over and above honors of education and learning
Contents
Preface.......................................................................................................................xi
Acknowledgments................................................................................................... xiii
Author....................................................................................................................... xv
List of Figures.........................................................................................................xvii
Abbreviations...........................................................................................................xix
Chapter 1 Industrial Transformation......................................................................1

Business Transformation.......................................................................2
Key Elements of Business Transformation........................................... 3
Organization Transformation...........................................................3
Business Process Transformation..................................................... 5
Technology Transformation..............................................................6
Industrial Transformation.................................................................6
Transformation in Industrial Manufacturing.........................................7
Future Industrial Transformation..........................................................8
Summary...............................................................................................8
Bibliography..........................................................................................9
Chapter 2 Engineering and Manufacturing Transformation............................... 11

Process Automation............................................................................. 12
Engineering Process Automation................................................... 12
Manufacturing Process Automation............................................... 13
Business Process Automation......................................................... 14
Robotic Process Automation.......................................................... 15
Practice of RPA in Supply Chain.............................................. 16
Digital Process Automation............................................................ 17
Intelligent Process Automation...................................................... 17
Necessity for Process Automation....................................................... 18
Process Transformation....................................................................... 19
Process Automation to Process Transformation..................................20
Challenges to Incur......................................................................... 21
Value Drivers of Process Transformation...................................... 22
Summary............................................................................................. 22
Bibliography........................................................................................ 23
Chapter 3 Technological Innovations of Industrial Revolution 3.0 to 5.0............25

Industrial Revolution...........................................................................25
First Industrial Revolution..............................................................25
Second Industrial Revolution......................................................... 27
Third Industrial Revolution............................................................28
vii
viii Contents
Programmable Logic Controller................................................ 29

SCADA...................................................................................... 30
Industrial Robots....................................................................... 31
Fourth Industrial Revolution.......................................................... 32
Internet of Things......................................................................34
Industrial Internet of Things...................................................... 35
3D Printing................................................................................ 36
Augmented Reality.................................................................... 37
Data Analytics........................................................................... 37
Simulation.................................................................................. 38
Fifth Industrial Revolution............................................................. 39
Collaborative Robots.................................................................40
Artificial Intelligence................................................................. 42
4D Printing................................................................................ 43
Challenges of Industry 5.0..................................................................44
Benefits of Industry 5.0.......................................................................44
Summary............................................................................................. 45
Bibliography........................................................................................ 45
Chapter 4 Transformation in Automotive Sector................................................. 47

Process Revolutions............................................................................. 48
Six Sigma........................................................................................ 49
Toyota Production System.............................................................. 49
Lean Manufacturing....................................................................... 49
World-Class Manufacturing........................................................... 50
Business Necessity for Process Transformation.................................. 51
Process Transformation Revolutions................................................... 52
Implementing PLM for SMEs........................................................ 53
Business Challenge.................................................................... 53
Precondition............................................................................... 53
Approach.................................................................................... 53
Result�� 54
Implementing Process Control System (PLC, SCADA) for SMEs.... 54
Precondition............................................................................... 55
Approach.................................................................................... 55
Result��55
Heat Treatment Process.................................................................. 55
Business Challenges.................................................................. 56
Precondition............................................................................... 57
Approach.................................................................................... 57
Result��57
Predictive Maintenance in Heat Treatment Process....................... 57
Additive Manufacturing................................................................. 58
Virtual Reality and Augment Reality............................................ 59
Quality Standards........................................................................... 59
Contents ix
Business Challenges in Process Transformation.................................60

Bridging Process Revolution to Process Transformation.................... 62
Summary.............................................................................................64
Bibliography........................................................................................ 65
Chapter 5 Transformation in Hi-Tech Electronics Industrial Sector................... 67

Trail toward Digital Ecosystem........................................................... 68
Process Automation Revolutions......................................................... 69
Electronic Design Automation....................................................... 69
Failure Process Analysis................................................................ 70
Transformation in PCBA Process.................................................. 72
PLM for PCB Design..................................................................... 72
Precondition............................................................................... 73
Approach.................................................................................... 73
Result��74
Quality Assurance.......................................................................... 74
Industrial Robots............................................................................ 74
Process Transformation Revolutions................................................... 75
Simulation....................................................................................... 76
Augment Reality............................................................................. 77
Additive Manufacturing................................................................. 78
Robotic Process Automation.......................................................... 79
Process Standardization of SMT....................................................80
Cobots��81
Artificial Intelligence..................................................................... 82
Business Challenges of Process Transformation................................. 82
Bridging Process Automation to Process Transformation................... 83
Sustainable Design through Manufacturing...................................84
Summary.............................................................................................84
Bibliography........................................................................................ 85
Chapter 6 Transformation in Process and Industrial Manufacturing Sectors..... 87

Solar Photovoltaic (PV) Industry........................................................ 87
Process Automation and Transformation in Solar Energy Sector.... 89
Automation in Solar Power Plant............................................... 89
3D-Printed S olar Panels............................................................90
RPA-Enhanced Solar Energy Sector.........................................90
Incorporating AR in Solar Energy Sector................................. 91
Impact of IoT on Compact Linear Fresnel Reflector (CLFR)........ 91
SMART Solar Power Plant.............................................................92
AI Application in Solar Energy Sector......................................92
Extrusion Process Industry.................................................................. 93
x Contents
Process Automation Potentials....................................................... 95

Process Automation to Transformation..........................................96
Simulation in Optimizing Process Flow....................................96
AR Scope in Plastic Industry....................................................97
AM Advances Plastic Manufacturing.......................................97
Environment Management System............................................ 98
Outcome of Transformation........................................................... 98
Ground Support Equipment in Aviation Industry................................99
Process Automation to Transformation..........................................99
AR/VR Improve MRO in Aviation GSE................................. 100
AM Applied in Aviation GSE.................................................. 100
Outcome of Transformation......................................................... 101
Valve Industry.................................................................................... 101
Process Automation to Transformation........................................ 102
Simulation Support Valve Manufacturing Industry................ 102
IIoT in Valve Manufacturing Industry..................................... 103
Summary........................................................................................... 104
Bibliography...................................................................................... 105
Chapter 7 Upgradation of Industry 4.0 to Industry 5.0...................................... 107

Business Need for Industrial Transition............................................ 107
Challenges in Industrial Transition................................................... 108
Mitigation of Industrial Transition Challenges................................. 109
Industrial Transition Strategy Planning............................................. 111
Strategy Planning—Internal Factors............................................ 111
Strategy Planning—External Factors........................................... 113
Business Use Case............................................................................. 114
Business Challenge....................................................................... 114
Precondition............................................................................. 115
Approach.................................................................................. 115
Result��116
Workplace of the Future.................................................................... 117
Summary........................................................................................... 118
Index....................................................................................................................... 121
Preface
The rate of modern technology creation and fostering certainly varies across different
industrial sectors. Technology is frequently progressing, and production must develop
with it to stay competitive. While Industry 4.0 is still the primary transformation for
many manufacturing leaders, it’s crucial to look toward the future. In the industrial
sector, the Internet of Things represents an effective modern technology driving a lot
of the modifications since the introduction of the Industrial Internet of Things, pro-
viding significant benefits to manufacturers from different industries. This publica-
tion endeavors to provide a glimpse of how small to medium enterprises and original
equipment manufacturers can best leverage, increasing the process effectivity, opera-
tional effectivity, reducing unskilled workforce utilizing Industry 3.0 to Industry 4.0
through Industry 5.0, will definitely lead to the manufacturing of greater worth tasks
than ever before, driving optimum outcomes from human-to-machine interactions.
I have always had a passion for advancement in product lifecycle management
and computer-integrated manufacturing. Being a PLM and IIoT business consultant,
I’ve had opportunities to assist manufacturing enterprises to enhance their business
processes, finding methods to fix issues and help them start off their transformation
journey. I feel obliged to share my knowledge along with my experience. I hope that
the information and expertise offered here will awaken business leaders, product
design and development professionals, manufacturers, industrial automation profes-
sionals, IT professionals, consultants, and academies to come to the realization that
to improve engineering process, they need production effectivity, quality, and zero
waste manufacturing ecosystem.
I wish you enjoy your reading.
xi
Acknowledgments
I would certainly like to express my gratitude to several individuals who saw me through
this book; to all those who offered assistance, talked things over. Thanks to Cindy Renee
Carelli – Executive Editor, Erin Harris – Senior Editorial Assistant, my publisher CRC
Press/Taylor & Francis Group: without you, this book would certainly never find its
place in the digital world, and to a lot of individuals throughout this global village.
I thank Joel Stein for revealing the course to authoring this book.
I would like to thank my friends – Subject Matter Experts, who took part in the design
thinking process – S. Palanivel, E. Srinivas Phani Chandra, A. Babu, K. Manikannan,
V. Venkataramanan, V. Bhuvaneswaran, D. Gopinath, K. Gopinath, R. Selvaraj, E.
Kamalanathan, N. Ganesh, S. Rajaprakash, P. Saravanan, A. Kalidhas, and P. Baskar.
I express my love and gratitude to my parents, my wife – Saranya Uthayan, my
son – U. Neelmadhav, my professors, my good friends, associates in the business, and
all my well-wishers, without whom this book would not have been possible.
xiii
Author
Uthayan Elangovan has 17 years of dynamic experience, ranging from product life-
cycle management (PLM) to Industrial Internet of Things (IIoT) consulting for an
assortment of businesses, including automotive, electrical, medical, industrial, and
electronics enterprises. He helps and leads PLM, IIoT usage, and subventures, and with
cutting-edge collaboration tools and techniques, he gives consultations to worldwide
clients. Energetic about PLM, IIoT, and its effect on product development guarantee-
ing PLM, IIoT system meets client deliverables while supporting business processes.
His interest in making technological advancements in automation influenced him to
write his first book Smart Automation to Smart Manufacturing – Industrial Internet
of Things, which was named as one of the Best Manufacturing Automation books of
all time by Book Authority. His passion for PLM and IIoT influenced him to author his
second publication Product Lifecycle Management (PLM): A Digital Journey Using
Industrial Internet of Things (IIoT), which was named as one of the Best Industrial
Management books of all time, New Industrial Management books to be read in 2021
and New Product Design books to be read in 2021 by BookAuthority.
He earned a bachelor’s degree in mechanical engineering from Kongu Engineering
College and a master’s degree in computer-integrated manufacturing from PSG
College of Technology. He currently resides in Tamil Nadu, India, and is a consultant
for PLM and IIoT, providing business and education consulting through his firm –
Neel SMARTEC Consulting.
xv
List of Figures
FIGURE 1.1 Simple transformation process...........................................................2
FIGURE 1.2 Organization transformation..............................................................4
FIGURE 1.3 Business process transformation – ERP implementation...................5
FIGURE 2.1 RPA role in medical device segments.............................................. 15
FIGURE 3.1 Mechanical revolution......................................................................26
FIGURE 3.2 Science and technology revolution................................................... 27
FIGURE 3.3 Digital automation revolution........................................................... 29
FIGURE 3.4 Automation levels............................................................................. 31
FIGURE 3.5 Cyber-physical revolution................................................................. 33
FIGURE 3.6 Function of IoT.................................................................................34
FIGURE 3.7 IoT vs IIoT........................................................................................ 36
FIGURE 3.8 The future of the industrial economy............................................... 39
FIGURE 3.9 Applications of cobots...................................................................... 41
FIGURE 4.1 Implementing PDM: Foundation of PLM........................................ 54
FIGURE 4.2 Shop floor process control automation............................................. 56
FIGURE 4.3 IIoT and cobot in heat treatment process......................................... 58
FIGURE 5.1 Automation defect mapping process in test station.......................... 75
FIGURE 5.2 Defect mapping transformation using AR....................................... 78
FIGURE 5.3 Process standardization of SMT line using IIoT..............................80
FIGURE 7.1 Transformation journey based on different factors......................... 110
FIGURE 7.2 SWOT analysis of industrial transformation.................................. 112
FIGURE 7.3 PESTLE analysis of industrial transformation............................... 113
FIGURE 7.4 Process transformation-mapped framework................................... 115
FIGURE 7.5 Before—traditional inventory monitoring system.......................... 116
FIGURE 7.6 fter—the future smart connected inventory monitoring
A
environment.................................................................................... 117
xvii
Abbreviations
ADAS Advanced Driver Assistance System
AGV Automated Guided Vehicle
AI Artificial Intelligence
AM Additive Manufacturing
AMS Aerospace Materials Specifications
APC Advanced Process Control
APQP Advanced Product Quality Planning
AR Augmented Reality
ASPICE Automotive Software Performance Improvement and Capability
dEtermination
BOM Bill of Material
BPA Bisphenol A
BPM Business Process Management
CAD Computer-Aided Design / Drafting
CAE Computer-Aided Engineering
CAM Computer-Aided Manufacturing
CAPA Corrective Action Preventive Action
CAx Computer-Aided technologies
CFD Computational Fluid Dynamics
CFT Cross-Functional Team
CIM Computer-Integrated Manufacturing
CNC Computer Numerical Control
CRM Customer Relationship Management
CTQ Critical to Quality
CQI Continuous Quality Improvement
DL Deep Learning
DCS Distributed Control System
DFA Design for Assembly
DFF Design for Fabrication
DFE Design for Environment
DFM Design for Manufacturing/Design for Manufacturability
DFMEA Design Failure Mode and Effect Analysis
DFR Design for Reliability
DFT Design for Testing
DFSC Design for Supply Chain
DFSS Design for Six Sigma
DFx Design for Excellence
DPA Digital Process Automation
DMAIC Define, Measure, Analyze, Improve, and Control
DMT Defect Mapping Tool
DOE Design of Experiments
DRC Design Rule Checks
xix
xx Abbreviations
EaaS Energy-as-a-Service
eBOM Engineering Bill of Material
ECAD Electronic Computer-Aided Design
EDA Electronic Design Automation
EMS Electronic Manufacturing Service
Ems Environment Management System
ERP Enterprise Resource Planning
ESD Electrostatic Discharge
ESG Environmental, Social, and Corporate Governance
FMEA Failure Mode and Effects Analysis
FEA Finite Element Analysis
FEM Finite Element Method
FDA Food and Drug Administration
GRN Goods Receipt Note
GPU Ground Power Units
GSE Ground Support Equipment
HMI Human–Machine Interface
IATF International Automotive Task Force
ICS Industrial Control System
ICT Information and Communication Technology
IDOV Identify, Design, Optimize, and Verify
IEC International Electrotechnical Commission
IIoT Industrial Internet of Things
IoT Internet of Things
IPA Intelligent Process Automation
IPC Institute of Printed Circuits
IR Infra-Red
ISO International Organization for Standardization
IT Information Technology
JIT Just-In-Time
KPI Key Performance Indicator
M2M Machine 2 Machine
ML Machine Learning
MES Manufacturing Execution System
MSA Measurement System Analysis
MDM Medical Device Manufacturer
MRO Maintenance, Repair, and Overhaul
MRP Material Requirements Planning
MSD Moisture-Sensitive Device
MVDA Multivariate data analysis
MVP Minimum Viable Product
NC Numerically Controlled
NLP Natural Language Processing
NPD New Product Development
NPI New Product Introduction
OEE Overall Equipment Effectiveness
Abbreviations xxi
ODM Original Design Manufacturer

OEM Original Equipment Manufacturer
OCR Optical Character Recognition
PCB Printed Circuit Board
PCA Printed Circuit Assembly
PCBA Printed Circuit Board Assembly
PCA Process Control Automation
PCS Process Control System
PDM Product Data Management
PEEK PolyEther Ether Ketone
PESTLE Political, Economic, Social, Technological, Legal, and Environmental
factors
PLC Programmable Logic Controller
PLM Product Lifecycle Management
PMEA Process Failure Mode and Effects Analysis
PPAP Production Part Approval Process
PVC Polyvinyl Chloride
QFD Quality Function Deployment
QMS Quality Management System
RCA Root-Cause Analysis
RF Radio-Frequency
RFID Radio-Frequency Identification
ROI Return of Investment
ROV Return of Value
RPA Robotic Process Automation
RPN Risk Priority Number
SCADA Supervisory Control and Data Acquisition
SCARA Selective Compliance Assembly Robot Arm
SCM Supply Chain Management
SME Small to Medium Enterprise
SMT Surface Mount Technology
Solar PV Solar PhotoVoltaic
SPC Statistical Process Control
SWOT Strengths, Weaknesses, Opportunities, and Threats
THT Through Hole Technology
TPS Toyota Production System
TCP/IP Transmission Control Protocol/Internet Protocol
VPVC Unplasticized Polyvinyl Chloride
VSM Value Stream Mapping
VR Virtual Reality
WCM World Class Manufacturing
WEEE Waste Electrical and Electronic Equipment
1 Industrial Transformation
Manufacturing industries around the global village are on the threshold of great
opportunities that promise extraordinary development and transformation of their
business through smart products and smart manufacturing, enabled by cutting-edge
technological innovation. Industrial sectors sell their products thorough complex
processes such as research, design, development, manufacturing and service. Every
product manufacturing segment has unique challenges that cannot be tackled by a
one solution that fits all requirements. Manufacturing enterprises perennially encour-
age the development of science and technology and adopt a variety of approaches to
transform their businesses, thereby constantly seeking new ways to upgrade and dis-
tinguish themselves from their competitors.
Digitalization has heralded a new paradigm in manufacturing, where manufactur-
ing facilities are transformed to be extra modern and advanced. Consequently, this
arouses concerns in the minds of business tycoons: will the emerging technologies
take control of the manufacturing production line of futuristic factories? In a world
of burgeoning modern technology, many manufacturers stand to gain much from
automation, if the circumstances are exploited right. Taking automation to the next
level can be a huge advantage for the manufacturing industry. Advanced automation
can help reduce a holdup, reduce production expenses and enhance product quality.
Industrial sectors are reshaping their competitive landscape and steering in to a
new era of growth, change and economic opportunity. Every organization requires
their employees and machinery to do their jobs with greater efficacy and proficiency
while managing operations, designing products as well as establishing intellectual
property throughout the globe. The ultimate objective of industrial transformation
is to achieve a better quality of product and service for the customer. Current busi-
ness systems, including computer-integrated manufacturing (CIM), product lifecycle
management (PLM), enterprise resource planning (ERP), manufacturing execution
systems (MES), programmable logic control (PLC) and supervisory control and data
acquisition (SCADA) along with Industrial Internet of Things (IIoT), are now being
utilized to ensure that a superior user experience, quick time to value, integration of
information and easy access from anywhere across the globe are realized. Innovation
is making an impact on every stage action from product design to manufacturing.
Today, manufacturing industries are developing techniques for combining new
innovations to improve their efficacy and performance, the leading concept behind
Industry 4.0. It is essential to closely assess the elements of the business, from cli-
ent connections to reshoring options and likely a lot more. Robotics has emerged to
become the mainstay in production, and, Industry 4.0 innovations offer greater versa-
tility in manufacturing processes. Manufacturers can also introduce new automation
and artificial intelligence-assisted effectiveness to their enterprises. Heralding the
next industrial transformation calls for the adoption, standardization and execution of
new technologies, which requires its very own framework as well as advancements.
DOI: 10.1201/9781003190677-1 1
2 Industry 5.0
BUSINESS TRANSFORMATION
Business transformation is a strategic initiative on every business leader’s campaign
to remain competitive, which consists of workers, processes, as well as innovation to
achieve measurable enhancements in effectiveness, performance and complete cus-
tomer satisfaction. Organizations that continuously adapt are driven by a keen vision
to redesign their future via transformation. An improvement is a major change in an
organization’s abilities and identity to ensure that it can deliver valuable outcomes, per-
tinent to its objective, which it could not accomplish previously. Business transforma-
tion is more defined by a high level of passion of the organization as a substantial space
that should be linked in between the current and future enterprise path. It represents
an essential enhancement in the present b usiness operations. A robust commitment to
value expansion is an effective directive for identifying the efforts that will certainly
have the best influence on an enterprise transformation road map and also for under-
standing its prospective worth for investors.
Among the successful business change instances is Apple – from being a producer of
computer systems, Apple has slowly taken place to customer devices. Experts say the
shift has been smooth. After the launch of iPod, Apple changed from being a hardware
and software supplier, to the domain of customer electronic devices. With the launch of
iTunes Music store, Apple became a media business.
(Gupta and Perepu 2006)
Service improvement needs to consistently be a step in the right direction for a thriv-
ing business. Because of this, business transformations need to aim at making inroads
in to entering a brand-new section of the marketplace, adding industrial value to the
business, improving the efficacy of the manufacturing processes and making best use
Resource Input Transformation

Final Product
Process
Feedback and Continuous improvement
Man, Machine, Material Design, BOM, Production Planning Final end item delivered to
Control, Quality, Production Order, the customer and services
Manufacturing and Operation
Methods
FIGURE 1.1 Simple transformation process.

Industrial Transformation 3
of the available resources. Business advancement aspects differ for every manufactur-
ing enterprise. This is because every enterprise has their own strength to leverage and
difficulties to deal with. The path toward business transformation is never easy, as it is
fraught with challenges. Irrespective of the nature as well as the objective of the trans-
formation, all enterprises can anticipate significant resistance to change. For a success-
ful tranformation, the management must dare to take risks and must be steadfast and
meticulous in its execution. The success of a business transformation squarely built on
the ability of the enterprise to adapt to change in strategies often determined by mar-
ket change, disruptive needs and tactical direction. The ability of the management to
overcome these obstacles is one of these the crucial success variables.
KEY ELEMENTS OF BUSINESS TRANSFORMATION

Manufacturing industries need to direct their attention from mere survival to seek-
ing new methods to grow. Considering globalization and the fast pace of today’s
business, there are no quick fixes for simplifying business intricacies. Globalization
has made it hard to keep organizational frameworks simple. Today’s multinational
businesses have thousands of employees, numerous organization companions and
substantial operations spread across the globe. Following an appropriate enterprise
organization structure and also operating model is an ongoing battle.
Few questions that can help manufacturing industries to understand the need for
business transformation are as follows:
1. How pleased are the clients with your product and service?
2. What are the different ways to enhance client experience?
3. How to prosper in the current smart and connected competitive world?
4. How would certainly financial investments in technology improve the
experience?
5. How can success be determined?
Manufacturing industries cannot transform successfully unless their individuals

within the enterprise transform; majority of the transforming initiatives fail because
enterprise overemphasizes the tangible side of the transformation. Business transfor-
mations within an enterprise impact the monitoring of operational settings, interfere
with the cultural norms, modify service procedures and capitalize on new modern
technologies. Some examples of buissness transformations in industrial sectors are
as follows: organization transformation, technology transformation, business process
transformation and industrial transformation.
Organization Transformation
Organization transformation is a basic, enterprise-wide change impacting how a com-
pany is run while focusing on augmenting its efficiency and proficiency. Organization
transformation is a term that refers collectively to activities such as reengineering,
revamping and redefining organization systems, and it happens in response to rapidly
changing demands and the compulsive need to improve the enterprise’s efficiency
along with sustainability. It shows the measures adopted by the business leaders
4 Industry 5.0
to steer the business successfully into the future and to achieve the desired result.
However, if the company perceives delays in its quarterly reports, it might have a
much more substantial issue on its hands. As every business experiences cycles of
development along with change, this is an oppurtunity to analyze the performance
of the company and prepare a strategic plan for its future. What is required is an
alternative procedure that companies can utilize to help them incorporate as well as
implement changes throughout the organization.
Google achieved organization transformation by developing higher division. Research
and development division dealt with such a variety of projects that it was ending up
being tough for management executives to concentrate on innovation. Tactical solution
devised is splitting right into several business entity, each of them with a slim focus,
responding to the new parent firm Alphabet.
Alphabet Inc. (2017)
Maintaining a keen eye on both the problems will provide an insight into whether or
not any organization transformation is needed. Change is usually driven by C-level
executives who are in charge of process of the organization. It is important for the suc-
cess of any transformation program that the organization rightly identifies the real-
ity and is prepared to adopt the required procedures without losing focus as the
organization transformation initiative is implemented. Transforming an organization
requires the ability to be agile, receptive to market trends and technology, whenever
essential. These adjustments are lasting only when they affect the end users to alter
their actions and influence supervisors to adapt and approve brand-new concerns.
Organization transformation is more likely to do well when the organization agrees
to accept the change and when the scheduled modification is integrated well with
existing business control systems and also culture. Transformational changes call for
Support and Measure
Review Progress Define Change

Transformation
Organization
Define Goal and Vision

Implement Change
Communicate Change Review Impact Define KPI and Plan
FIGURE 1.2 Organization transformation.

considerable advancement besides learning. Business participants need to discover

exactly how to enact the new ways and carry out new approaches. Regardless of the
level of the organizational transformation, it is critical that the organizational effect
and threat analyses are carried out to permit C-level executives to recognize the
resources necessary to efficiently execute the modification effort and to establish the
impact of the modification on the organization.
Business Process Transformation

Business process transformation is the essential rethinking of a process within an
enterprise. This focusses on the end-to-end placement of the main purposes, mea-
sures, information, metrics and innovation in accordance with the strategic goals and
also the tactical needs of the business, delivering a significant, calculated increase
in client value. It entails an assessment of the actions called for to attain a specific
objective in an effort to remove replicate process tasks. Identifying a process will
aid in saving time, speed up the return on investment and return on value and save
sources. It is essential to recognize the best alternatives in order to pick the best tech-
nology and application plan to sustain both business process transformation needs
and strategic goals. Primarily, business process transformation is driven by market
needs and entails automating as many procedures as possible.
“Siemens Vision 2020, which outlined an organizational overhaul, restructuring, and
also calculated shift from energy and also commercial manufacturing to digitaliza-
tion.” “Philips Split its lights core from its medical care growth company, changing
itself into a health care modern technology firm.”
(Anthony et al., 2019)
Deployment,
GAP Analysis TO – BE Process
AS – IS Process Business Use Testing, Go live
And Buy In
Case and Support
Analyze current
and future state
Process Mapping
Develop use case
scenarios
Existing manual matching the Future automated Automated
Process business process business processes Production
within the followed by Planning and
enterprise management buy-in Scheduling on the
Map the process floor
to ERP functional
FIGURE 1.3 Business process transformation – ERP implementation.

6 Industry 5.0
Business process transformation is a deliberate and organized extension of the

transformation journey that garners a substantial return on investment leading to
breakthroughs in an organization’s efficiency outcomes. Whatever the target or nature
of the business change, the goal is always to reinforce its relevance in the competitive
market in order to guarantee its survival. Thus, business process transformation is a
beneficial goal and a vital building block for any significant and calculated changes
made within the enterprise. It is arguably a crucial action in every kind of service
modification. During the COVID-19 pandemic, several transformational fads were
set to speed up, swiftly. Many companies in different industrial sectors were under
tremendous stress to quickly adapt their service designs in this radically altered mar-
ket conditions in order to stay sucessful. The most significant risk to any effective
business process transformation is aligning it with a suboptimal data method. Like
organization transformation, business process transformation too requires cautious
planning, clear objectives and confident administration.
Technology Transformation
Technology transformation is a vital part of competitive business practices today
in this smart connected world. Most of the industrial application systems used in
the enterprise are attracted by new cutting-edge technological advancements by
innovative companies with response to expectations of customers. These enterprises
are consistently evolving their internal information technology ecosystem to mini-
mize hazards and simultaneously boost business continuity. Industry 4.0 is currently
sweeping the industrial economic scene in a manner similar to the impact of the mass
media and communications on the industry over the past decade.
Innovation in every industrial sector supports the creation of all new, digitally
enabled business models, while holding out the important assurance of boosting
consumer experiences and enhancing the productivity of legacy process. The infor-
mation and communications technology revolution is transforming conventional
sectors, ensuing changes and big modifications in well-established ecosystems.
Advanced innovations are vital to modern business, and, it is fair to claim that every
big manufacturing sector needs to move toward this transformation to attain growth.
Technologies transformed the method individuals functioned, but they did not funda-
mentally alter the way businesses ran. Certainly, technological innovation can itself
be a driver for massive organizational changes such as the method by which employ-
ees interact with each other and the manner in which the business engages with
customers, companions and also various other stakeholders engage. The COVID-
19 pandemic has augmented the demand for driving technological transformation
across businesses of all dimensions. Enterprises are welcoming remote jobs and
swiftly customizing their daily procedures to match the new normal.
Industrial Transformation
Industrial sectors are continuously growing and transforming by seeking essentially
new methods to enhance monetary assets besides functional performance, safety and
security, high quality and competitive advantage. One of the main developments is the
exchange of information between during various stages of the customer service. Industry
leaders often challenge their internal groups to come up with the most effective and
innovative ways to transform their businesses utilizing digital innovations, improving
value chain processes and through collaborative work environment to serve the markets
better. An effective industrial transformation requires not only innovation but also a shift
in the perspectives of the people who eventually apply and also utilize the new processes.
TRANSFORMATION IN INDUSTRIAL MANUFACTURING

Technology is omnipresent and continues to transform numerous sectors particularly
the production market. Business enterprises need to continually update on technical
development, if the industries have to remain competitive, which implies that manu-
facturing services need to be aware of what is the best and also the most recent innova-
tion. Innovative methods are adopted in the process of selecting the material and made
use of in the manufacturing process; this has made the process less labor-intensive
and much safer, consequently boosting the operation. The use of computers and smart
devices each day has actually boosted the performance of the enterprise residences,
offices and manufacturing facilities are being managed utilizing smart tools, and the
industrial sector’s transformation trajectory is progressive. The demand for smart
products is surging, calling for new and ingenious manufacturing approaches, and
numerous producers have actually stepped up to the next level of industrial transfor-
mation. Recognizing the nature of the change in the production sector will certainly
aid to establish which methods are likely to prosper and which will not.
At the end of the eighteenth century, manufacturing industries steered away from
the artisanal approach and moved toward machine-assisted work, and when electri-
cal power was utilized in manufacturing facilities, it led to real mass production
becoming a viable choice. Possibly, one of the most impactful changes has been
the transition to automation. The introduction of computers in production became
more and more noticeable, with digital systems being developed to oversee a whole
assembly line. Presently, customers want things faster and also better, customized
and distinct. Consequently, manufacturers have to not only find a method to maintain
the demand for products but also find skilled workers to make these products.
The advancements in technology and the consequent growth of the industry have
improved the status of the business and gained the trust of its customers. Scientific
research and development along with computer simulation in product advancement
as well as other locations have made a significant influence. Every new advancement
has brought a change in the production process that has in fact transformed the way
the industries function across different sectors. Generally, the growth of industrial
transformation shows the complete understanding of how technological innovation
improves the growth of manufacturing industry. The application of industrial robots
along with artificial intelligence is on the rise and they are much more sophisticated
and proficient at doing intricate jobs. Even the expense differential with human beings
is narrowing, to the advantage of robotics.
Transformation from analogue, mechanical, along with digital innovation,
describes the path to digital innovative technology. Bridging the gap between design
and manufacturing through services and making use of big data, data analytics and
8 Industry 5.0
machine learning transform to the fourth industrial revolution. Understanding the

importance of data generated across the manufacturing enterprise opens up oppor-
tunities for the evolution of new business models that transition from being product
centric to customer-focused service centric.
FUTURE INDUSTRIAL TRANSFORMATION

A great deal of the innovations that are in practice currently are facelifts of the fun-
damental ideas laid throughout the transformations that took place so far. The fifth
industrial transformation, also known as Industry 5.0, is already becoming part of
the industrial automation landscape. Industry 5.0 combines human creativity and
workmanship with the rate, effectiveness and also consistency of robots. Moreover,
it complents human beings by whetting their creative thinking. Industry 5.0 creates
even higher-value tasks than Industry 4.0, due to the fact that human beings are
reclaiming product design through manufacturing that calls for creativity.
Robot guides, group control directed by artificial intelligence and also immersive
virtual reality are among the technologies, allowed by the internet of things, set to
delight fans at Tokyo’s 2020 Olympics. Robots (Field Support Robot, Remote Location
Communication Robot, Human Support Robot, Delivery Support Robot) established
by the Toyota Motor corporation will certainly help spectators in a series of tasks, from
carrying food and also various other items to showing people to their seats and also
supplying information on occasions. The robotics also help functional real-life imple-
mentation aiding individuals, besides visitors in mobility devices.
(Olympics, 2019; Forbes, 2019)
To strike a balance wherein the machine-human interaction can supply the highest
possible benefits, where increasingly complex processes will certainly call for an
ecosystem that is capable of handling the substantial amount of information gener-
ated and also provide human operators with a room that they can utilize to connect
with shop floor machines with the development of digital twins. Industry 5.0 com-
bines human creativity and robotic accuracy to engender a distinct option that will
soon be in demand of the coming years. Both Industry 4.0 and Industry 5.0 have
paved a road map that industries can/shall follow in order to sustain.
SUMMARY
Technology-driven transformation requires the appropriate organization culture and
management executives to function appropriately. Modern technology alone is not
enough to drive these transformations; business leaders need to engage with their
workers to encourage understanding and adoption. Manufacturing industries that
takes care of to foster the appropriate culture to incorporate these new technologies
will be the ones with a competitive advantage, improving their existing business
models, developing new possibilities, all the while retaining time-tested skills and
simultaneously drawing in brand-new skills. Strategic investments continue to be
vital for every manufacturing organization’s ongoing development; even if different
aggregating techniques in varied operations can be made complex, the process can
aid manufacturers to see high returns in the increasingly competitive environment.

This is really a future that provides value to the manufacturing. A key aspect in
improving business performance is having the most efficient processes and the most
effective people, focusing on a client’s outcomes and using cutting-edge technol-
ogy to identify areas for improvement to leverage engineering process effectiveness
through manufacturing effectiveness across the different levels of the enterprises.
BIBLIOGRAPHY
Alphabet Inc. 2017. Reorganizing Google (Case Code: HROB185). Hyderabad: IBS Center
for Management Research (ICMR).
Anthony, Scott D., Alasdair Trotter, Rob Bell and Evan I. Schwartz. 2019. Transformation-20.
Boston, MA: Innosight.
Becker, J., M. Kugeler and M. Rosemann. 2010. Process Management: A Guide for the Design
of Business Processes. Germany: Springer.
Bradford, M. and G. J. Gerard. “Using process mapping to reveal process redesign opportuni-
ties during ERP planning.” Journal of Emerging Technologies in Accounting 12 (2015):
169–188.
Engel, A., T. R. Browning and Y. Reich. Designing products for adaptability: insights from four
industrial cases. Decision Sciences 48, no. 5 (2017): 875–917.
Forbes. 2019. https://www.forbes.com/sites/stevemccaskill/2019/07/29/
tokyo-2020-to-use-robots-for-a-more-efficient-and-accessible-olympics/.
Gupta, Vivek and Indu Perepu. 2006. The Transformation of Apple’s Business Model Case
Study (Case Code: BSTR212). Hyderabad: IBS Center for Management Research
(ICMR).
Hammer, M. and J. Champy. 1993. Reengineering the Corporation: A Manifesto for Business
Revolution. New York: Harper Business.
Harrington, H. J., D. R. Conner and N. F. Horney. 1999. Project Change Management: Applying
Change Management to Improvement Projects. New York: McGraw-Hill Trade.
Kane, G., D. Palmer, A. Phillips, D. Kiron and N. Buckley. 2015. Strategy, Not Technology,
Drives Digital Transformation. Texas, MIT Sloan Management Review and Delloite
University Press.
Madison, D. 2005. Mapping, Process Improvement, and Process Management: A Practical
Guide to Enhancing Work and Information Flow. Chico, CA: Paton Press.
Manganelli, R. L. and M. M. Klein. 1994. The Reengineering Handbook: A Step-by-Step
Guide to Business Transformation. New York: AMACON.
Olympics. 2019. New Robots Unveiled for Tokyo 2020 Games. https://olympics.com/ioc/news/
new-robots-unveiled-for-tokyo-2020-games.
2 Engineering and
Manufacturing
Transformation
Manufacturing organizations aim to integrate a varied set of functions such as qual-
ity control, supply management and so on to collaborate in a streamlined way. Having
stated that, the primary focus on business enterprises is automating a variety of product
development activities such as functional designs, procedures management, system sim-
ulations and recurring performance analysis of each step in the manufacturing of a part.
The process of bringing information technology-driven automation in design and pro-
duction tasks requires process automation in engineering through manufacturing. By
reducing the time to carry out each activity, companies can achieve significant financial
savings throughout the enterprise. The ideation behind automation is not recent; the con-
cept of using automation has actually been in practice for years; however, it has become
more popular and essential for certain industries in the last hundred years. Throughout
Industry 1.0, Industry 2.0 and Industry 3.0 automation had been mainly implemented
in industrial grounds; Industry 4.0 integrates industrial automation with information
and communication technology. With industrial automation, the objective was clearly
to boost the effectiveness of manufacturing customized products. Automation of a few
crucial processes can enhance the efficiency of specific processes, which is one of the
most persuading factors for organizations to take on process transformation.
From medical component to industrial component manufacturers and from auto-
mobile manufacturers to aerospace and defense sectors, finding innovative methods
to reduce expenses and save time to market while consistently supplying high-quality
products will be an essential element for all industrial sectors. The business enter-
prises are perpetually nurturing out-of-the-box thinking as well as revamping the
business process and utilizing new methods to transform the conventional approach
to design. CIM along with computer-aided engineering (CAE) innovation supports
the collaborative processes required to make a substantial impact on the product
design life cycle, enhancing functional performances besides lowering prices. PLM
supports to handle a vibrant set of engineering files that maintain a history of design
changes and ensure that new product development/new product introduction (NPD/
NPI) teams are always working with the most recent updated product data. It sustains
design effectiveness by giving a solitary resource of the right information, accessible
in the best context. As rises in computer advancement in product design and devel-
opment rise exponentially, advanced sensing unit technology, robots and artificial
intelligence (AI) control systems along with various other technology developments
pave the path to the future wherein smart manufacturing impact seems positioned for
a remarkable change in many industrial sectors.
DOI: 10.1201/9781003190677-2 11
12 Industry 5.0
PROCESS AUTOMATION
Industries encounter several difficulties as globalization continues to decrease the
earnings margin, but at the same time, they are required to produce quality prod-
ucts and services. Automating everyday tasks ensures procedures are carried out in
a prompt manner, without missing out on the target date. Automation predominantly
takes over all the labor-intensive tasks, making it possible for an organization to speed
up operations substantially with few mistakes. With enhanced effectiveness comes
increased capacity, making it easier to scale operations as the business grows. Process
automation allows members of the NPD team to carry out even more innovative jobs
that are more rewarding and satisfying; this contributes to the organization’s success.
It is essential to have a business strategy that combines more practices to simplify
complex processes. Process automated workflow-enabled product development pro-
cedure can be used to enhance, standardize and shorten the development cycle.
Process automation is an essential function of digital transformation
Introduction of new product into the market is one of the basic strategies for any type
of manufacturing industry. New products are introduced in the market annually as
customers are looking out for more assortment of products. High competition forces
business enterprises to reduce the cost of the new product development to comply
with a quantifiable process to produce renewed market offerings. Development of
process automation entails the assimilation of process, people and data along with
software applications throughout the enterprise to automate process-oriented tasks.
Enterprises that are not able to produce new products to the market can experience
the repercussions. Integrated automated process can connect spaces and in addition
break down silos to advertise partnership in between various groups and also parts
of business, helping with cross-functional team involvement.
Process automation is appropriate for type of industrial sector, although each sec-
tor has distinct business policies that control how tasks are executed. Implementing
process automation might differ for different industries, e.g., product information
management comprises of product lifecycle management, enterprise resource plan-
ning, supply chain management, and customer relationship management. There
is still dilemma in the minds of small to mid-size manufacturers on whether pro-
cess automation is the the most essential thing that the enterprise needs right now.
Financial investment in automation ought to belong to a broader area in the product
design and manufacturing process. Plainly, this ought to be lined up to the enterprise
strategy planning. Initiating partial automation is a much more practical objective
for some enterprises, particularly small to medium enterprise (SME) manufacturers.
They remain in a tough spot while considering how to take the right steps toward
embracing a new technology along with the business processes.
Engineering Process Automation

Automation in product design and development is one possibility to sustain prod-
uct designers in their everyday work. Design processes are complicated and include
cross-functional teams that include sales, advertising and marketing, designing,
Engineering and Manufacturing Transformation 13
manufacturing and quality control. Assimilation of customer needs and market

demands is directed to product developers and designers. Manufacturers intend to
bring a diverse collection of cross features to interact in a structured fashion. Process
automation in designing easily accomplishes this for SME manufacturers, besides
providing quicker reaction to market needs. Product design and process layouts have
been in practice for years in different industrial sectors. Even a small initiative in
automation can boost the efficacy of many individuals procedures, as it is one of the
most convincing factors for an enterprise to adopt process automation. Engineering
process automation allows product manufacturers at all levels to turn around propo-
sitions swiftly, design and manufacture effectively and cater more efficiently to con-
sumer demands and generate a healthy, competitive and balanced revenue.
Product manufacturers utilize a series of engineering applications for process
automation systems such as CAx which includes CIM consisting of computer-aided
design (CAD) and computer-aided manufacturing (CAM) and CAE which have
control over process automation. Integrated product database permits an enterprise
to focus on its data management efforts along with lifecycle management. Product
configuration practices can be superimposed on top of product data management
features. CAx tools along with product data management (PDM) and PLM make it
possible for engineering changes, assisted in with the product configuration manage-
ment to be better created and also evaluated to define changes to be implemented in
new product development and new product introduction process.
Engineering process automation aids manufacturers in enhancing the design,
analysis and manufacture of products. The journey of engineering process automa-
tion starts with preserving the particular of the product and process design details
electronically, which will reduce paper-based representations. This reduces hand-
drawn drawings and the storage of papers; it also minimize the time to access the
most updated version of a part along with its associated drawings and reduce errors.
Making use of these technologies and combination concepts effectively improves the
communication regarding the product and process design within the design function
and across the extended enterprise and clients.
Manufacturing Process Automation

Manufacturers are always looking out for ways to reduce the production operation
cost as well as speed up the manufacturing process without compromising on the
end product quality. It has motivated manufacturers throughout all industrial sectors
of all segments to automate business workflows, along with integrating other enter-
prise systems. Manufacturing processes automation is one such critical component
of nearly all product manufacturers across the globe. It provisions the information
needed to take care of the shop floor operation as a whole. Products can be tracked
from ideation, creation, right to the customer.
Business enterprises attain better productivity by installing manufacturing auto-
mation in all operations and interaction leading up to manufacturing. Manufacturing
process automation is the topmost priority of most manufacturers. It aids to carry
out operations along with tasks such as processing, production setup, examination,
inventory management and production preparation. Manufacturers are additionally
14 Industry 5.0
integrating real-time dynamic surveillance, quality management, ERP though MES

to acquire greater precision, range and faster time to market. The main function is to
reduce the manufacturing lead time, reduce wastage and ultimately boost the produc-
tivity qualitatively and quantitatively.
Some of the manufacturing process automation tools available for manufacturers
are as follows:
• Distributed control system

• Programmable logic controller
• Supervisory control and data acquisition
• Human–machine interface
• Artificial neural network
These are used to integrate the flow of inputs from sensing units and events with the
passage of results to actuators, instrumentation, movement control and robots.
Business Process Automation

Constant changes in customer needs as per the latest market trends in the industry,
quick decision-making and delivering quality customer service along with running the
organization more efficiently can be achieved with the help of business process auto-
mation (BPA). The core principles behind the BPA function are orchestration, integra-
tion and automated execution. With automated processes in position, enterprises save
time and make sure that the finest techniques are applied to improve general func-
tional effectiveness. In the age of Internet-enabled manufacturing, process automation
has risen to become the most sought after innovation that delivers the finest service to
both internal and external customers. BPA has become the norm of process standard-
ization for process quality and constant improvement, with a combination of enter-
prise systems such as PLM, ERP and MES. The arrival of Industry 4.0 technology
Industrial Internet of Things (IIoT) connected machines to the digital environment; it
enabled the movement of information over a network with no human communication.
Process automation and management is the foundational structure of product lifecy-
cle management. It automates and also accelerates repeatable production business pro-
cesses such as product design modification demands, authorizations, engineering and
manufacturing change orders, along with automated workflows. Process monitoring
brings a methodical approach to the tasks executed by both the NPD team and enter-
prise system. Most of the recurrent approval or review processes with a well-known
reasoning in the product maturity model can be enhanced with PLM-based process
management. Taking full advantage of the extent of the product growth process, PLM
can be leveraged besides being recognized with the help of BPA. It enhances the new
product development process, elevating their capacity to use product details to make the
most effective general selections around which component to make, and how to build it.
One of the most vital parts of organization process automation is that it gets
rid of silos throughout the manufacturing enterprise. Adopting process automation
gives us the capability to access and also interpret service information throughout
the business from the production line procedures to the business besides throughout
the supply chain. Yet, at times, manual operations and disconnected systems can
impede the ideal information from reaching the correct area at the correct time.
Manufacturing enterprises make the best use of financial investments in existing
modern technology and also attain higher degrees of interoperability than fea-
sible with manual processes. Data access is less complicated and search details
can be recorded over time, as it is electronically captured and stored in the cloud.
Additionally, BPA is a substantial property to conformity procedures enforcing dis-
cipline, simplicity, and effectiveness right into the process.
Robotic Process Automation

Industrial manufacturing sector has predominantly seen automation equipped by
physical robots that put together, examine package the products and aid in stream-
lining the assembly line. In contrast, robotic process automation (RPA) is a type of
software robot that imitates the activity of a human being in performing a task within
a process. It can do recurrent tasks more quickly, accurately and consistently than
people. RPA allows the manufacturing enterprises to focus additionally on product
technology and core strengths rather than the daily repeatitive jobs that are essen-
tial but mundane in nature. RPA can be thought of as an electronic spine linking
all applications. Manufacturing companies are incorporating digitization into their
processes to enhance development, high quality and also performance. With RPA,
manufacturers can update their production procedures and also service functions,
accomplishing high productivity and labor reduction.
Functions
Medical Device Segment
Inspection of Data Interpret and process

Clinical trial data
Content Extraction, Data extraction from DHF

Updating And DMR
Natural Language
Processing (NLP)
Report generation, Automate and Track –
Workflow Automation Training assignments
Virtual Workforce, Auditing of FDA

Orchestrate task Compliance
Robotic Process
Process Automation Automation – Software
Support Pharmacovigilance
-Repeated Task Robot
FIGURE 2.1 RPA role in medical device segments.

16 Industry 5.0
RPA technology can considerably assist in automating more applications such as

supply chain process, product design, advancement and assistance to provide even
more worth in the long term. RPA in manufacturing has absolutely become a vital
enabler for procedure automation. The primary action initiated in the production ser-
vice where RPA is incorporated is the selection of one of the most effective organiza-
tion procedures to attain automation. The RPA automates processes such as extracting
and updating details from numerous enterprise applications such as PLM, ERP, SCM
and logistics companies that are incredibly taxing and also prone to errors.
RPA is not a replacement for the underlying business applications; instead, it sim-
ply automates the current manual jobs of the employees. One of the essential benefits
of RPA is that the devices do not change the extant systems or infrastructure. It is a
crucial tool in automating obstacles within the manufacturing enterprises pushing to
grow toward their digital transformation journey. Technologists around the world are
trying to upgrade automation efforts by infusing RPA with cognitive innovations in
automating higher-order jobs.
Practice of RPA in Supply Chain

At the core of supply chain exists inventory control tracking. Distributors constantly
require information regarding their supply levels to ensure they have sufficient prod-
ucts besides spares to meet customer requirements. RPA makes supply tracking
simple by preserving details on supply levels, thereby informing the supply chain
managers when the product supply levels decrease, and additionally reordering items
right away. Business enterprises such as retail and production across markets have
trusted applications such as PLM, ERP, MES, RFID, CRM and SCM. Of these, sup-
ply chain tracking uses RPA to automate common, low-value jobs, which simplifies
procedures in the supply chain while eliminating human error.
RPA allows supply chains to scale up quicker to make certain that they can stock
up supply as demand boosts. RPA figures out the needed stock levels and matches
them versus the available supply. It automatically initiates the increase in order that
travels up the supply chain without relying on human initiation. Order handling
procedure gets automated along with payment such that information can be straight
consumed right into the business data application. Negotiation happens through
the portal, which can refine the recommended amount, besides send out e-mail
along with SMS message confirmation for the positioning of order. As of today,
with the arrival on AI, numerous supply companies trust bots to automate situa-
tions and refining them too, and by automating this back-office work, organizations
can assure their workers concentrate on excellent quality tasks that require human
intelligence.
The implementation of RPA is not as easy as it sounds; it requires proper
planning at each stage and strategizing the execution procedure and a cclimatizing
the mindset of the employees of the enterprise; all these would certainly assist
to develop the tone for alteration. If an enterprise aims to work with a digital
technological improvement service provider, it needs to proceed with the end
to end implementation initiative of Industry 4.0 in enterprise supply chain to
avail full advantage along with return of value (ROV) and return of investment
(ROI).
Digital Process Automation

Digital process automation (DPA) is advanced, digitized as well as automated, which
is similar to typical business process management (BPM). DPA is a holistic strategy
toward automation, which collaborates various modern technologies to transform the
entire organization. DPA improves on the conventional BPM to aid organizations to bet-
ter optimize end-to-end processes and to support enterprise-wide transformation. DPA
assumes that business processes have currently been digitalized and focuses on opti-
mizing the existing workflows to enhance the customer and end-user experience rather
than incurring. Organizations that have experience with BPM ought to have the ability
to easily execute DPA. DPA looks to automate not just business functions but also data
monitoring within the business to make information available in real time. Essentially,
DPA assists companies to transform into digital, data-driven businesses via automation
and encourages employees to make data-driven decisions. Process automation can take
care of numerous jobs as well as interactions, bringing together different information
systems to supply manufacturers much less variantion between processes, improved
data honesty and storage space, much more effective and open to the shop floor process.
Straightforward day today issue that DPA can address immediately goes out stock and
supply replenishment of resources allowing the smooth circulation of details and auto-
mation of little work to let the internal team and customers understand when basic
materials are back in supply. Implementing DPA is simply one of among the most
essential improvements making enterprises can make throughout the transfer.
(Watts, 2020; Bizagi, n.d.)
In this fast-paced smart connected challenging digital transforming world, manufac-

turers need to focus on innovation and performance to remain ahead of the competi-
tion by swiftly automating processes to supply excellence. DPA has a massive scope
of advancement with IIoT, artificial intelligence (AI) and machine learning (ML)
along with intelligent robots. Data play a big role as they make use of cloud-based
options and help in evaluating the collected information to fulfill consumer demands
and also improve the production process. Generating the silos of details from each
other will certainly improve product design, promote manufacturing renovation,
speed up delivery and boost end customer experience.
Intelligent Process Automation

The introduction of digital transformation across manufacturing industries integrates
the internal business processes, thereby automating all interactions with the customer
effortlessly. Business leaders adopt automation strategies to find the ideal process that
result in minimizing the waste, improves cost efficiency and guarantees a better con-
sumer experience. Consumers have extremely high expectations these days; hence,
most manufacturing enterprises operate at an increased rate. Product manufacturers
are expected to be a lot quicker in their response. Utilizing dynamic data to generate
the most relevant results has become mandatory. Therefore, welcoming automation as
become a vital method of functioning in today’s world. Industry leaders are beginning
to head in the direction of new innovations called intelligent process automation (IPA).
18 Industry 5.0
The idea of automation in the digital globe is gaining ground and technology
is advancing with machines becoming more adept in performing human tasks.
Innovations in digital modern technologies, accessibility of sensing units and
enhanced computing power as well as storage have resulted in increasing its reach
far in the worldwide technological landscape. It is the innovation that makes it pos-
sible for organizations to automate processes that involve structured, semi-structured
and disorganized file systems consisting of records, text, photographs, videos, etc. It
efficiently performs activities carried out by people. Some core modern technologies
that develop the structure for intelligent process automation are AI, natural language
processing (NLP), optical character recognition (OCR), smart workflows and RPA.
Manufacturers can make use of predictive analytics to fix brand-new issues and
also promote product engineering. Machine learning models are being used to antici-
pate just how to produce specific physical products and also lessen anomalies in
intricate material properties. The implementation of IPA helps the manufacturers to
save time that would otherwise be invested doing computations to notice anomalies
prior to a product enters quality assurance. IPA has set off industrial transformation
in both Industry 4.0 and Industry 5.0, radically changing the processes and settings
that depend on cyber-physical and cognitive systems.
IPA is the next level in the development of process automation and integrates
artificial intelligence capabilities typically with process automation. It is developed
to help employees by taking over repeated, regular jobs. It mimics human activities,
without the demand for human intervention.
NECESSITY FOR PROCESS AUTOMATION

The most important variable that determines profit besides client satisfaction is pro-
cess automation. Automating process in the business enterprise can be profitable, as
it reduces expenses and improves the efficacy of the tasks.. Automation conserves
money and time; however, what is right for one enterprise may not be right for an
other. Moreover, the tasks that can be automated and the extent of automation are all
factors that require consideration.. Determining the appropriate automation required
can be an obstacle, yet it should not prevent the manufacturing organization from
beginning to apply automation within the processes followed.
Developing strategies as well as formulating the real road map for automating
the process is the first and foremost step to do. Nonetheless, strategy throughout the
organization has its share of obstacles. Nevertheless, there are many business enter-
prises utilizing some kind of process automation within their business.
I can think of an easy and most widely seen examples is that of even a small enterprise
do follow process automation in the business is “Automatic reply” mail from the cor-
porate email account to the clients.
(Luther, 2020)
Today’s fast-growing industrial economic pressures have considerably impacted the

effectivity and efficiency of the industries encouraging them to adopt the process
of automation. With leaner operating budgets, organizations can no longer man-
age to waste money on time-consuming and also tiresome jobs. The key reason for
automation to have been welcomed so widely is its potential to yield higher results
and increased productivity, aiding both cross-functional team members and other
services. Innovation in robotics, industrial vision, IIoT, AI and cobots have opened
lots of new capacities, allowing automation to be used not only in mass production
processes but also in high-mix low-volume production environments.
Process automation levers numerous tasks, exchange of information, bridges the
gaps as well as paves the path toward business process transparency across the enter-
prise. It involves running design data management, bill of material, vendor devel-
opment and production planning control workflows by compiling information from
CAD, PDM, PLM, ERP and MES.
As modern technology continues to become more advanced each day, manufactur-
ers have the ability to run the business enterprise with leaner operating budgets, and
designing, evaluation and other procedures are being replaced by smart process and
smart machines that eclipse the abilities of human beings. Business decision-makers
desire their shop floor machines to deliver the highest possible result with as little pro-
duction expense as feasible. Process automation is very effective as it helps to increase
design and manufacturing effectiveness, product and process quality, by reducing
human assistance and the risk of errors. A majority of the manufacturing industries
started to implement Industry 4.0 to process automation, which is considered to be a
good indicator in the direction of digital transformation. Right automation technology
coupled with the right skilled workers will position the buisness enterprise for suc-
cess; the enterprise ought to begin the digitalization process in a stepwise method to
meet the organization goal toward transforming in to a digital enterprise.
PROCESS TRANSFORMATION
Transformation is essential for many functions within a manufacturing enterprise.
The journey starts with an effort to address a specific challenge, and soon after, the
firm recognizes that they can implement the transformation and benefit if expanded
throughout the enterprise. Initiating process transformation is one of the most efficient
means to increase product quality along with operational performance. The leading
concern of most manufacturing sectors is to improve quality. Process transformation in
an industrial sector deals with quicker responses to market demands, and it goes to the
core of the business process transforming it to take advantage of the digital capabilities.
As the rate of industry accelerates development becomes vital; enterprises are
required to upgrade their strategies and processes to get new products off the attract-
ing board as well out into the market rapidly. Yet, individuals who carry out the job
of creating new products and designers are usually the most resistant to change. Most
importantly, quality control approach includes decreasing risks, boosting training,
and developing much better processes, besides making the work environment much
safer and cleaner for everyone who spends time within it. The introduction of high
quality transformation commences by getting rid of manual manufacturing process
and also transitioning to touchless manufacturing. Incorporating business processes
transformation into the decision-making process not only aids organizations get
more worth out of their financial investment in innovation but also addresses issues
concerning employees, helps them acclimatize to the transformation better. Overall,
20 Industry 5.0
organizations are required to comprehend that utilizing modern technology to trans-

form their businesses is fantastic, but the trick to succeed hinges on learning what
ails the business using modern technology and correcting those issues before discov-
ering novel uses of any kind of new age innovation.
As modern technology continues to progress exponentially, it has become impera-
tive for firms to transform their process in order to secure a competitive advantage.
Business leaders in the manufacturing industry have actually been traditionally
reluctant to transform and introduce innovation due to the prices connected with
making those changes. Leverage process, knowledge, skills along with modern tech-
nology to recognize its complete influence of process transformation, which needs to
be part of the initial discussion ensuring future road map to success.
Transformation can just begin with a personal change of employees and by enhanc-
ing the process within the enterprise. Manufacturing ventures, be it small, medium
or big, all should be ready to prosper in a globe where overhead prices, produc-
tion operation cost along with resource cost are affordable. Furthermore, the orga-
nization will certainly need to specify the manufacturing objectives and set a clear
strategy for transformation. Process transformation succeeds only after substantial
thought has gone into identifying the potential improvement areas and enhancing
a strategy where technology enhances service, increases profits and also reduces
costs. Comprehending the different stages of the production venture maturity can
assist process automation with process transformation in the manufacturing industry
appropriately. It will certainly transform the way service is performed in every field
of the industrial economy.
PROCESS AUTOMATION TO PROCESS TRANSFORMATION

Process automation involves using modern technology to make processes run them-
selves, making those processes much more effective and efficient with analytic
reporting capabilities. The implementation of automation has reduced the time and
has enabled supplier interactions to take advantage of customer interactions with
quick, customized reactions at scale. In other words, process automation is a means
to achieve desired end result through process transformation. Client expectations
continue to soar high with the advent of new technologies, and many services are
embracing process transformation in an effort to remain relevant and fulfill client
expectations.
Path breaking buisness enterprises acknowledge that in order to remain competi-
tive, they must constantly improve their culture, processes, data and innovations;
attaining this requires extra planning and effort. Several enterprises are still reluctant
to earnestly improve their internal process in spite of the established effectiveness
of automation and digital transformation. Manufacturing enterprises have a solid
understanding about process streamlining besides automating the process to remain
competitive. One of the greatest influences of process transformation most likely
originated from innovation assisting, not changing or removing workers. These ben-
efits will just be recognized when automation is securely incorporated with organi-
zation procedures at all degrees of the organization and also customized to various
functions within the company.
For manufacturing enterprises, process transformation is the basis of Industry

4.0, the secret to updating and enhancing manufacturing operations. Transformation
impacts new product growth segment in a considerable number of ways. It drastically
changes the enterprise’s new product landscape. From obtaining basic materials, to
bringing products to the market, technology is now becoming omnipresent for pro-
ducers; modern technology is being incorporated up and down the production line
to provide information and determining real-time choices throughout the procedure;
thus, manufacturing is undergoing a fundamental change. It offers remarkable possi-
bilities for product developers in the production industry, not just to distinguish their
new products but also to improve the method these products are developed, created
and released. The paybacks are considerable, but so are the challenges in getting
process automation to process transformation right.
Challenges to Incur
Automation of business processes is at the heart of process change initiatives and is a
crucial parameter for success, although there are still challenges and demands to be
taken care of. Most of the procedures are significantly complicated and consist of vari-
ous actions and elements. Absence of a clear vision besides tactical oversight increases
the chances that vital service processes are mishandled, delayed or damaged recklessly
generating problems and affecting credibility. Few main challenges are as follows:
• Comprehend the need for process automation within the enterprise, even
before preparing for a process transformation. This is essentially imperative
as most stakeholders in the organization may not be prepared for a trans-
formation. People have various point of views, and although collaborations
succeeds at the outset, it might hold hidden reflexive conflict.
• As consumer demands continues to grow, adapting to the marketplace may
require a lot more investments that it might go beyond the actual spending
plan set previously.
• A well-laid out strategy requires a vision for the process transformation to
improve the existing core expertise and advance toward that vision.
• The transformation to become a customer-oriented enterprise requires con-
stant upgrading of the process.
• Understanding the impact that process transformation can have on an
organization.
• Resistance with respect to adopting new technologies that assist in process
transformation.
• Defining the metrics that can properly gauge efficiency prior to, during, and
after the process transformation.
• A lot of the challenges in attaining process transformation objectives are
social and behavioral.
Adopt the strategy of continuous progress in addition to stepwise progress toward

process transformation. While one can tackle the challenges as and when they arise,
it is also prudent to prepare beforehand to accelerate the ROI and ROV.
22 Industry 5.0
Value Drivers of Process Transformation

The transformation of a process in a manufacturing enterprise includes automating
various jobs in order to complete and in order to guarantee its survival. Developments
in electronics and technology have actually taken the world of economy and busi-
ness by storm. Automation will be favored for recurrent manual tasks and the costs
of robots besides their control systems will decline also in the future so small and
medium sized manufacturers can take advantage of them. Product development
organization will start making use of subtractive and additive processes and will cer-
tainly have a deep understanding of naturally derived frameworks and digital tools.
Production operation will be extra carefully tied to either the place of the resources
or the location of the consumer. Wearables and powered exoskeleton will boost
human performance and improve safety. Smart machines are progressively func-
tioning effectively in the process sector and are expected to perform many routine
jobs in production and warehousing. Manufacturers are having a hard time drawing
in the ideal sort of ability they need as it has in fact become very sophisticated and
extremely progressive in numerous ways.
Smart manufacturing ability to check and monitor online makes it possible to
bring data-driven choices to human tasks to enhance the performance of systems
and processes and save time. Eliminating shop floor operation concerns during the
development process by making use of Industry 4.0 bars such as advanced statistical
process control (SPC) and electronic performance administration can be beneficial.
Quality and speed are the first things that are enhanced in this connected environ-
ment, which, in turn, assures something that all suppliers desire: an improved client
service experience. Copyright protection is another main challenge in an increas-
ingly distributed worldwide manufacturing ecosystem. Process standardization
lowers the price of entry for suppliers to carry out even more kick start process
improvement, and these drivers interrupt and transform the process in the production
sector irrevocably.
SUMMARY
Organizations across the globe are changing quickly, driven by emerging digital
innovations. Manufacturers of small, medium and large enterprises use process auto-
mation together with process transformation, which is likely to become the standard.
Transformation in the manufacturing sector is commonly comprehended to mean the
adoption of electronic technology to replace or automate manual procedures. Product
manufacturers, today, deal with a transforming business standard, in which emerging
modern technologies are permanently transforming how products are manufactured
and service is provided. With unprecedented data availability, product options and
network alternatives, consumers are demanding an ever-increasing level of transfor-
mation, not simply in products and services but also across the whole procurement
and product use experience. To get rid of delays, minimize accidents, eliminate mis-
takes, improve product quality and develop new organization standards, automation
innovations are increasingly imperative in today’s manufacturing industry. The race
to determine and also cater to ever-changing client requirements is getting intense
with the advent of new players with unique business models. Process transformation
indicates transforming standard procedures in to more efficient digital systems that
can boost performance dramatically, improving all aspects of the procedures.
Thanks to transformation of manufacturing industries, the manufacturing facili-
ties of the future will be more effective in the utilization of robots, material and
renewable energy along with human resources. Services and product improve-
ments suggest developing new value-added services that can both boost the produc-
tion environment and the consumer experience while opening brand-new revenue
streams. Major changes on the demand side are also happening with increasing trans-
parency, consumer involvement and brand-new patterns of customer habits, which
are increasingly built upon their accessibility to mobile networks and information,
pressure manufacturing enterprises to transform the method they create, market and
provide the products along with services. New modern technologies make products
much more resilient, while information besides analytics is changing exactly how
they are maintained. Manufacturers will begin exploring the journey in the midst of
the inexorable transition from easy digitization to technology based upon combina-
tions of innovations through the collaboration of human knowledge with bots toward
a future that reflects typical objectives as well as values compelling the firms to
review the means of how they work.
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3 Technological
Innovations of Industrial
Revolution 3.0 to 5.0
Manufacturing technology pledges to influence every facet of the production services
from design, research and development, manufacturing, supply chain to sales and mar-
keting. Industrial manufacturing sector processes raw materials into new products,
which are eventually utilized by customers, and also, it is influenced by the commer-
cial transformations that are taking place rapidly. Technology along with innovation
is the vital driver of advancement in manufaturing besides performance improvement.
New technologies combined with cutting-edge product designs provide manufacturers
numerous chances to improve the core business value, especially for small and medium
sized enterprises. To improve product development, manufacturers can engage differ-
ent modern technology tools as the first step toward digital transformation.
INDUSTRIAL REVOLUTION
In the contemporary period, manufacturing facilities are often transformed by
technology-based industry hubs. Trade expansions were made as a result of the trans-
formation from an agricultural economy to an industrial machine-driven economy
beacuse the automation of design and manufacturing of products through services
resulted from the quick development of the technology across different industrial
sectors. The primary revolution that occurred during the industrial transformation
was the renovation, execution and adoption of technological innovation. The recent
development of technology innovation is a recurring journey; the speed of innovation
and transformation continues to enhance. Transformation is not new to industrial sec-
tors; it is considered as a significant resource of industrial economy. Organizations
run by business leaders’ with a clear vision toward digital transformation upgrade
their business models to promote business growth, stay relevant in changing times,
and distinguish themselves from the competition, being able to think artistically and
welcome innovation right into their product lines.
Let us have a look at the brief overview of different industrial revolutions.
First Industrial Revolution

Changes commenced at the end of the eighteenth century and continued until the
beginning of the nineteenth century in the industrial sectors in the form of automa-
tion. The first industrial revolution was a major turning point in the background
of the human culture and was also called as the age of mechanical manufacturing,
DOI: 10.1201/9781003190677-3 25
26 Industry 5.0
Invention of Steam Engine

Industry 1.0
Industries,
Farmers,
Production Factory Household
Benefits
Fundamental changes
in Mills, farming,
Spinning machine and Growth of factories,
Power Loom Rural-to-Urban
migration
Technological
Innovation
Cotton Grid, Wrought Iron
Introduction of Steam boats,

Locomotives
Mechanized
Transformation
FIGURE 3.1 Mechanical revolution.
where products made from hand tools were transformed to products that were
made by machines. With the invention of the spinning jenny and the use of power
began the era of industrial revolution. Garments were made much quicker than
ever before. With the advent of the steam engine, steam power powered everything
from agriculture to apparel manufacturing. The product business, especially, was
changed by automation, as was transportation. Power generated from heavy steam
and coal made manufacturers discover new industrial use. The steam-powered
locomotive revolutionized the transport of goods. Additionally, it assisted in the
development of cities, and the quick expansion of, consequently, the economy
expanded together with them.
James Watt’s advancement consisting of a separate condenser significantly enhanced
heavy steam engine efficiency besides incorporating a crankshaft and gears became
the model for all modern steam engines. His discovery was considered one of the
most effective creations of the Industrial Change.
(Famous Scientists, n.d.)
It was more affordable to have a machine than having individuals that would have
to be waged. There occurred a paradigm shift from an agriculture-based economy
toward machine-based production. As a result of these advantages, for the right or for
the worse, man-made machines are all still being utilized as we speak. Throughout
the industrial transformation, environmental pollution increased because of the use
of the new fuel, the development of large manufacturing facilities and the surge of
unsanitary metropolitan facilities. The first industrial transformation was a time that
initiated lots of socioeconomic reforms together with several of the most functional
technological wonders.
Innovations of Industrial Revolution 27
Second Industrial Revolution

Numerous technological innovations in the industrial sector aided the introduc-
tion of the internal combustion engine, innovation of electrical energy, use of steel,
chemical sectors, alloys, petroleum and electric interaction technologies. The current
manufacturing and the production techniques of the first industrial revolution were
improved by the technological transformation, which marks a stage of rapid auto-
mation. Advancements in production technology, materials and manufacturing tools
are made to standardize all kinds of goods made in the manufacturing landscape.
Science and technology innovation work together, where science reveals effective
insights that drive technical development. Numerous innovators, understanding the
benefits of internal combustion over heavy steam, tried their hand in utilizing energy
in the automobile field. The development of continuous flow processes with inter-
changeable parts, usually related to production line, led to the automobile industry
setting up a plant to standardize mass production of intricate products.
Invention of electric light by Thomas Edison made a huge impact in the manufactur-
ing sector, made the operations to run three shifts per day. Technology of three-axis
system by Wright brothers, that made the airplane to maintain security also steadi-
ness, happens the basic principle continues to be the identical likewise today in the
aviation field. The electric generator technology adds to modern family products such
as refrigerators and laundry equipment’s, in addition with the innovation of internal
combustion engine enabled both automotive as well aviation field.
(Stanley, 1931)
Telephone, radio, conveyor belts, cranes and machines are all powered by electrical
power. Likewise, hydroelectric power plant and coal-based steam power plants were
Invention of Electricity and

Industry 2.0 Electric Light
Industrial
Sectors,
Household,
Introduction of Mass Benefits
Manufacturers,
Production Business
Electrical power
Manufacturing Assembly started step-in to
Line using conveyor residences,
manufacturing
facilities and farms.
Automobile industry
Invention of Telegraph, saw huge development.
Television, Radio and Passenger vehicle is
Telephone introduced for
Technological
transportation
Innovation
Infrastructure
Development
Start of electrified
transformation
FIGURE 3.2 Science and technology revolution.

28 Industry 5.0
developed. Steel use increased in the place of iron, in the construction of ships, high-
rise buildings and larger bridges. The influence of the industrial revolution on finan-
cial development and performance was far more absolute than any type of technical
advancement and it contributed to the global merger of markets coupled with the
first industrial transformation. Thanks to all of the developments and inventions, the
second industrial transformation can be summarized as a positive and advantageous
time in history. The inventions of the electrical energy, automobiles, and aircraft in
the beginning of the twentieth century are some of the reason for the second indus-
trial transformation to be considered as one of the most vital ones.
Industry 2.0 introduced processes leading to improved product quality and manu-
facturing effectiveness and efficiency such as just in time (JIT) and lean principles to
enhance Industry 1.0. Equally, first and second industrial transformation made con-
spicuous contributions for the development of the industrial sector. We cannot reject
on the fact that automation and industrial transformation have caused some unfavor-
able effects to the globe. Nevertheless, endorse the words of Heraclitus – change is
the only constant in this world.
Third Industrial Revolution

The second half of the twentieth century saw a surge in computer systems, automa-
tion, robotics, renewable energy, nuclear energy, electronic devices, telecoms, the
Internet and digital revolution, what is called as the third industrial revolution. In
the second half of the twentieth century, the industries were often affected by tech-
nological advancements and unpredictable market variations and international com-
petitors. Typically, a manufacturing industry in order to sustain itself and be relevant
in the competitive world of production needs to make production systems that not
only create high-quality products at cost-effective expense but also adapt quickly to
the marketplace transformations and consumer requirements; besides, the production
environment should have absolutely no machine downtime.
The implementation of automation during Industry 2.0 and the automation of
manufacturing shop floor lines with the digital uprising was a significant leap onward
in Industry 3.0. Industrial machine manufacturers started improving the perfor-
mance of the machines incorporating integrated circuits. The era of automation was
spearheaded within the automotive sector it was eventually embraced throughout all
manufacturing sectors. Industry 3.0 promoted the growth of software application
systems to capitalize on the electronic hardware.
Electronic devices along with information technology started to automate man-
ufacturing and also take supply chains global. Complex and recurrent jobs were
performed by software programs, making it possible for process automation in the
workplace, in the product design and in the manufacturing. Innovations in computer
assistance, the advancement of microprocessors and the advantages related to
computerized process control were recognized in the industrial sectors. While there
were many substantial technological innovations throughout this period, it is the
emergence of computer-assisted applications, such as computer-aided design, com-
puter-aided manufacturing, computer-integrated manufacturing, computer numeric
control, enterprise resource planning, material requirement planning, customer rela-
tionship management, supply chain management, rapid prototyping, product lifecycle
CNC Machines,
Industry 3.0 Industrial Robots
All Industrial
sectors
Benefits
Semiconductors
Computers were
into be volved in
Computers,
manufacturing as well as
Industrial and Process
in other sectors..
Automation
Hardware industry
started booming;;
Automation in the shop
Nuclear, Renewable floor, Mobile –
energy telecom, application
devices and internet.
Technological
Innovation
CAD, CAM, CIM, ERP,

MES, PLM
Start of digital automation
transformation
FIGURE 3.3 Digital automation revolution.
management, manufacturing execution systems, programmable logic control, super-

visory control and data acquisition (SCADA), which enabled the NPD/NPI teams to
strategize routines and track product streams through design and development within
the manufacturing process.
Programmable Logic Controller

A programmable logic controller (PLC) is a computer particularly made to run under
severe industrial settings such as extreme temperature levels, damp dry, and dirty
conditions. It is a compact industrial computer system created to manage manu-
facturing system process from one place. Simply put, it is an industrial solid-state
computer that keeps an eye on inputs and outcomes and makes logic-based decisions
for automated processes as well the shop floor machines in the assembly line. PLCs
play a critical role in the field of automation, making use of creating part of a big-
ger SCADA system. The range of PLC features are timing, counting, determining,
comparing, and handling different analog signals. PLCs are usually referred to as
industrial computers.
Technical breakthroughs in handling communications are generating new avenues
for industrial automation. Regardless of the fast developments in modern technology,
PLCs remain to play an important function in production and also work as a central
processing unit for all actual time decisions. PLCs help in identifying, monitoring
and getting rid of waste and also come to be more recognized as the world of auto-
mation control caters to the world of modern-day information and communications
technology. Supervisory control systems play a vital role in the manufacturing indus-
try as a move towards more open design standards, which enable interaction between
conventional PLC systems and other manufacturing control systems.
30 Industry 5.0
PLCs are used to control detailed features of the batch process with continual closed-
loop control along with extra controllers supervises the complete operation. As well
used to manage linear and also rotating actuators in an industrial fluid power circuit.
PLC are suitable gadgets for regulating an industrial robot operation.
(Laurean, 2010)
The vast majority of consumer products are manufactured at a production center,

delivered via a circulation network and supplied to a store and to the consumer making
use of automation. Manufacturers’ usual objectives behind implementing automation
tools depend on a couple of aspects such as high dependability, high repeatability and
simplicity of delivery beyond maintenance. Based on these principles as well as the
need of the manufacturing section, PLCs were created. Industrial automation in this
new age is practical in the form of technical advancement that basically supervises
the performance of various kinds of machines in the industry. A human–machine
interface (HMI) enables a user to productively manage a PLC in real time. The main
benefits of utilizing PLCs in industrial sector array from exceptional performance
to decrease in expenses. PLCs assist in identifying mistakes and also detect quality
deficiencies early on in manufacturing and neutralizes them intentionally. Cross-
checklists, component scans and completeness checks using PLC are some steps of
manufacturing surveillance that ensure optimal quality in manufacturing.
SCADA
SCADA is an automation centralized control system that checks and regulates whole
sites, ranging from an industrial plant to a complex manufacturing plant. Industrial
organizations began to use relays and timers to maintain some degree of supervisory
control without needing to send individuals to remote places to interact with each
tool. Increased usage of microprocessors and PLCs increased the business’ capabil-
ity to monitor and manage automated processes. With the adoption of modern ICT
requirements, today’s SCADA enables real-time plant details to be accessed from
anywhere across the buisness enterprise.
SCADA allows an organization to meticulously research and anticipates the opti-
mum action to gauged conditions and implement thoses actions immediately each
time. SCADA systems make use of distribution control systems (DCS), process con-
trol systems (PCS), PLC and remote terminal units (RTU).SCADA assists in reduc-
ing manufacturing waste and boosting the overall performance by providing relevant
and comprehensive production information to the drivers and also the administra-
tion. SCADA handles parts lists and for just-in-time manufacturing as well as con-
trols industrial automation and robotics. It ensures high quality in addition to process
control in production shop floor.
A common inquiry might arise in the minds of small and medium manufactur-
ing enterprises, who are new to automation is whether both PLC and SCADA are
the same or different and how they needs to be utilized within the enterprise. Two
of the most important technical advancements within manufacturing industries are
SCADA and PLC. Both the technologies work together to offer essential services.
PLC is a physical equipment, whereas SCADA is a software application. SCADA
is made to operate in a much more comprehensive range given that it can check and
gather information from every result of a system, whereas PLC, on the other hand,
focuses on keeping an eye on just one aspect within the system.
SCADA helps companies enhance their operational effectiveness. It refines real-
time information so that the control team has up-to-date, precise information to
make smart decisions. It manages operations, enhances effectiveness and reduces
downtime. Moreover, the system provides sophisticated warnings and effective
maintenance, helping manufacturers to minimize damage.
Industrial Robots
Automation has been adopted by many industries. The advancement of machinery on
top of other technological developments replaced manual labor. The advancement of
numerically controlled (NC) devices and the increasing popularity of the computer
both led to the generation of the first industrial robots. Robots have become an essen-
tial part of today’s huge manufacturing industries; they are microprocessor-controlled
and smarter besides having a greater degree of operational flexibility. Competitors
from firms faced a high need for commercial robots. So, what is a robot? I layman’s
terms, a robot is a machine that is capable of carrying out regular and also intricate
actions that are set by engineers.
Industrial robotics has the ability to considerably improve the quality of the prod-
uct and also form an inalienable part of the contemporary production landscape.
Applications are performed with accuracy and efficiency. As machines continue to
develop and handle increasingly complicated tasks, all manufacturing procedures will
soon be automated and taken over by robots. Most of the enterprises – SMEs or OEMs –
are incorporating the use of robotics in their contemporary manufacturing facilities.
Machine Level Information Technology Production Floor

Device Level Enterprise Level
Level Level
Comprises Selective
Hardware- compliance
assembly robot Dedicated Shop
Actuators, floor network, Shop floor and Information tracking
Relays, Sensors, arm, PLC,
Robot, CNC OPC server, DCS Software – SCADA, and monitoring for
Valves, RFID MES, ERP Decision makers
and so on. machine, AGV
and shop floor
machines
FIGURE 3.4 Automation levels.

32 Industry 5.0
The most frequently utilized industrial robots are selective compliance assembly
robot arm (SCARA), articulated, Cartesian, gantry and delta robots. Robots are the
future of production, and they provide suppliers increasing opportunities to mini-
mize prices, boost manufacturing and remain affordable.
The first generation of industrial robots had limited intelligence, freedom and
also functional levels of liberty. Human beings might experience exhaustion as a
result of the recurrent nature of their work, which can cause them to make errors.
Robots, on the other hand, can stay clear of making such blunders as a result of
their dexterity and high degrees of machine learning. The impact of automation in
production spreads far and wide, boosting efficiency and success of the whole manu-
facturing enterprise. Robots positively influence production by taking on recurring
jobs, streamlining the general setting of operations and teaming up with humans for
product manufacturing. Even small to medium sized enterprises are realizing the
significance of integrating robotics into their process for long-term benefits.
Fourth Industrial Revolution

The application of computers and automation in Industry 3.0 opened new possi-
bilities for advancement in industries with smart as well as self-governing systems
fueled by data and machine learning, what is being called now as Industry 4.0 or
the fourth industrial revolution. Today, in the smart connected world, automation
no more indicates stand-alone robots running independently of each other rather;
industrial markets are seeing much more robust, automation solutions, which take
advantage of big data, the industrial Internet of things (IIoT) and data analytics.
By integrating software and hardware, manufacturers can maintain a comprehensive
control over their entire operation.
Industry 4.0 enhances the computerization of Industry 3.0. When computers
were introduced in the manufacturing industry as part of Industry 3.0, the process
of incorporating a brand-new modern technology was not easy for many. Now, in
Industry 4.0, computers are interconnected with each and function independently
sans human participation.
Industry 3.0 find ways to measure and analyze processes to identify restorative
actions for enhancement, which paved the course to utilize highly efficient statistical
tools, such as Statistical Process Control (SPC), and the seven Quality management
tools. The process involved information collection, which permitted the techniques
of plan–do–check–act (PDCA), six Sigma (Define, Measure, Analyze, Improve,
Control) to be used, which can assist manufacturing industries to improve their exist-
ing techniques and advancements and also make them more effective with the help
of Industry 4.0 technologies.
The real power of Industry 4.0 lies in the integration of cyber-physical systems
with IIoT, which makes the smart manufacturing facility a fact. Emerging smart
machines that are getting smarter as they get accessibility to more data and manufac-
turing procedures will become even more effective. To dive deep in, cyber-physical
solutions transform an industry to be enhanced by wireless connectivity, keep track of
and monitor the business enterprise from a remote place and take independent deci-
sion, thereby adding a new dimension to the production process. Machines, people,
processes and frameworks are integrated into a networked loop enabling the overall
monitoring to become highly reliable and a lot more streamlined.
Industry 4.0 is creating a new business value by increasing the outcome, asset use,
besides overall efficiency. It is not merely acquiring new technology and systems to
enhance the manufacturing performance: it is transforming the process by which
the manufacturing industry operates and expanding their presence across the globe.
The outcome of Industry 4.0 is that the cross-functional team (CFT) of the organiza-
tion shares refined, up-to-date, pertinent views of manufacturing along with business
process with lot more dynamic analytics.
Industry 4.0 is ready to take root throughout the manufacturing environment. By
understanding and also utilizing the modern technologies, manufacturing can indus-
tries journey toward digital transformation. It is the merely height of technological
innovation in manufacturing, but it still sounds as if machines are taking control of
the industry. It is absolutely a cutting-edge method of manufacturing technology,
which ensures manufacturers a new degree of optimization and efficiency.
Automation in the industrial sectors has progressed from making use of basic
hydraulic and also pneumatic systems to contemporary robotics. IoT/IIoT can be
applied in the manufacturing systems to make the shop floor operation simple with
an automated control system. Process automation advances from reducing human
interference in the systems to preventing carcinogen and enhancing efficiency and
effectiveness. Having successfully incorporated the technical advancements in the
past, the wireless-based automation system is being embraced in the various types of
systems in addition to making use of Industry 4.0.
Internet of Things, Digital

Industry 4.0 Twin
All Industrial
sectors and
Benefits households.
Simulation, Additive
Manufacturing
SMART Factory,
SMART Green energy,
Augmented Reality, Virtual SMART City, SMART
Reality Home, SMART
Farming, SMART
Wearable, SMART
Classroom, SMART
Cloud Computing, Hospital, Autonomous
Artificial Intelligence Vehicle, SMART
Connected World
Technological
Innovation
Big Data,
Predictive Analytics
Start of Digital
Transformation
FIGURE 3.5 Cyber-physical revolution.

34 Industry 5.0
For manufacturers across the globe, Industry 4.0 stands for a paradigm shift in
just how are industries run, as essential as the transformation from Industry 1.0 via
Industry 3.0. Without manufacturing, the economy of any country will absolutely
stumble, and it depends on the manufacturers to provide improved capacities and
optimal techniques to produce products. Leading key digital technologies associated
with Industry 4.0 are explicated as follows.
Internet of Things
Extending the power of the Internet beyond computer systems and also smart devices
to an entire range of things, processes, and environments made a huge impact to
both the industrial and business sector. When a physical thing is linked to the Web,
it implies that it can send out details or receive details, or both. The capability to
send out and/or obtain information makes things wiser and also smarter. As a whole,
Internet of things (IoT) is a network of uniquely recognizable things that interact
without human interaction, generally making use of IP connectivity. The semantic
origin of the expression is composed by a couple of words: “Internet” as well as
“Thing,” where “Internet” can be specified as “The worldwide network of intercon-
nected local area network, based on a conventional interaction process, the Internet
collection (Internet protocol suite – Transmission Control Protocol/Internet Protocol
TCP/IP),” while “Thing” is “an object not exactly recognizable”.
One of the best examples of IoT is remotely manage the on/off the lights as well moni-
tor water level in the overhead tank by means of your SMART mobile phone without
being physically present.
(Elangovan, 2019)
IoT / IIoT
Sensor / Devices Connection Information Handling Platform
WiFi, Zigbee, 4G LTE, 5G, RFID,
Bluetooth
Machines,
Sensors
RF Components , Data Storage and Processing of User Interface –
PC, Tablets, Data using Software Web app and
Mobile Phones, Mobile App
Wearables
FIGURE 3.6 Function of IoT.

In a nutshell, IOT is the inter-networking of physical devices, connected devices

and also smart gadgets, buildings, and various other products installed with elec-
tronics, software application, sensing units, actuators, and also network connection
which enable to collect as well as exchange data. The idea of including sensors and
intelligence to fundamental objects was reviewed in the 1980s through 1990s. Few
developments were introduced as Internet-connected vending machine was listless
since the innovation was not ready. Processors that were cheap and power-frugal
enough to be just about non-reusable were needed before it ultimately became
economical to link up billions of tools. The implementation of radio-frequency
identification (RFID) tags low-power chips, which can connect wirelessly, solved
several issues, in addition to the enhancing the availability of broadband along with
cordless networking. Adoption of IPv6 that, among other points, must offer enough
IP addresses for each device across the globe is also a necessary step for the IoT.
Industrial Internet of Things

Industrial Internet of things (IIoT) has become prevalent in the industry as digitization
has become the manufacturing enterprise’s top priority. Thus, IIoT is a subcategory
of the IoT, which consists of consumer-facing applications such as wearable devices,
smart factory, autonomous vehicles and robots. Sensors embedded in the shop floor
machines transmit data by means of intranet and are run software programs that are
the characteristic of industrial IoT. IIoT is changing the means industrial companies
operate daily by incorporating machine-to-machine interaction with large informa-
tion analytics in real time, and the IIoT can aid companies recognize their organiza-
tion procedures much better by assessing the information originating from sensors,
making their processes extra effective and open to new income streams. An IIoT
ecosystem is where individuals, applications and devices connect. That is why most
large industrial IoT services are based around a main industrial IoT system that can
manage every facet of the commercial IoT network and also the data streaming via it.
The key distinction between IoT and IIoT depends on the business application.
Industrial IoT centers around real-time collection besides evaluation of granular
information from linked sensors, allowing fast renovations to operational effective-
ness and also efficiency, instant stock control over and significant cost savings.
Basic components that are required for IIoT are as follows:
• Hardware
• Software
• Processing unit
• Cloud
• IIoT platform – System App, Mobile App
Manufacturing enterprises are eager to carry out connected factory, Industry 4.0 and
IIoT concepts to realize benefits, such as minimized operational prices, better expo-
sure, control, and operational efficiencies. These benefits can be accomplished by a
variety of means, one of which is making use of data gathered from keeping an eye on
factors along a production line to reduce waste and downtime. As a crucial element
of digital transformation, adopting IoT technology is imperative to the manufacturing
36 Industry 5.0
SMART Factory
SMART Home, SMART Industrial Internet
Internet of Things City of Things
Connected Medium – Sensors , Internet -> Real time

SMART Energy
SMART Hospital, SMART
Wearables
Response, Predictability
SMART Farming, SMART Robots,
SMART Toll Drones
SMART
SMART Wearables
Inventory,
SMART Tooling
SMART Gadgets SMART Asset

Management
Commercial Industrial
FIGURE 3.7 IoT vs IIoT.
sector. As the international market pushes manufacturers to reassess operations,

smart manufacturing powered by IIoT-driven data analytics is necessary. Digital
transformation of a conventional production procedure into a smart manufactur-
ing facility will be certainly advantageous for manufacturing enterprises of all
sizes.
3D Printing
Additive manufacturing (AM) is a 3D printing process that constructs 3D products
by adding layer upon layer of the product according to digital 3D CAD model
information. AM was originally used for quick prototyping, namely to make
visual and useful prototypes. It can considerably quicken the product development
process. 3D printing constructs a model in a container full of powder of either
starch- or plaster-based product. An ink-jet printer head shuttle uses a percentage
of the binder to create a layer. Upon application of the binder, a new layer of pow-
der is brushed up over the previous layer with the application of even more binder.
The procedure is repeated till the model is complete. As the model is sustained by
loosened powder, there is no requirement for support. Furthermore, this is the only
process that builds in colors.
AM opens brand-new opportunities in challenging markets such as the healthcare,
automotive, aerospace sectors, consumer goods together with commercial production.
3dprinting assistances on-demand manufacturing organization model stresses the price
of delivery as well the ability to produce extra components much faster in enhanced
manufacturing uptime and also much less production disturbances at the point of need.
(Gonzalez, 2021)
Design for manufacturing (DFM) frequently shows that designers need to customize
their designs to fit restrictions related to the conventional production treatments in
order to make sure the expediency of building the model. Nonetheless, this might
lead to restrictions and constraints in the designers’ innovative flexibility for new
product development. Conventional manufacturing techniques can produce a won-
derful range of designs; nonetheless, 3D printing takes manufacturing to the next
level. Among the greatest advantages of this modern contemporary technology is the
greater series of forms and shapes, which can be developed.
Augmented Reality
Augmented reality (AR) improves the physical world around us with the help of
modern technology. Innovation superimposes information along with online things
on real-world scenarios in real time. It makes use of the preexisting environment
and includes information to it to make a new artificial environment. It superimposes
digital information and photographs on the real world, promises to shut the space
and launch untapped, along with distinctively human abilities. AR applications are
provided with mobile phones, but progressively distribution will move to handsfree
wearables such as head-mounted displays as well smart glasses.
Utilizing AR technology for remote upkeep would permit any type of employee with an
AR device to be guided on a machine malfunction on the production floor by a profes-
sional located at his premises. Microsoft’s HoloLens mixed reality headset, a mix of AR
and virtual reality modern technology, has already been used by few manufacturers.
(Microsoft, n.d.)
Safety is constantly a concern in the manufacturing environment. In manufactur-

ing, the modern technology can be used to determine a range of changes, recognize
risky working problems or even envision a completed product. Wearable AR tools
for manufacturing shop floor workers lay over production setting up and also solution
directions, and it is supplementing traditional guidebooks, cookbooks and training
methods at an ever-faster rate. AR will definitely reinvent manufacturing, and busi-
nesses need to offer it major factors to consider.
Data Analytics
Data analytics in manufacturing is focused on collecting and evaluating information
instead of process control. Data from an endless variety of sources such as ERP,
MES and machines can be gathered as well as associated together to recognize areas
for enhancement. Improving the top-quality product by minimizing process varia-
tion has always depended on data. To lower functional risks as well as improve ser-
vice performance by leveraging advanced data analytics such as statistical analytics,
predictive analytics, and so on are very crucial questions that need to be considered,
currently in the smart connected manufacturing.
So, what is data analytics? It is the method of collecting insight by breaking down
past efficiency and also information to make sure that an insightful next step can be
intended and also taken. It describes the collection of measurable and qualitative tech-
niques for obtaining beneficial insights from data. One of the straightforward examples
I can think of is usage of data analytics by Amazon.com. It utilizes data analytics to
recommend the best item to the customer based on the item that they bought in the past.
38 Industry 5.0
SPC analysis uses the ability to boost the product quality and improve the process
efficiency and effectiveness, which is something that every manufacturing organization
demands. Importance of data analytics in manufacturing operations cannot be overem-
phasized. SPC is the keystone of quality assurance in manufacturing process. Over the
years, suppliers have used statistical devices to research historical data to expose details
relating to special differences between equivalent things: shifts, items, devices, proce-
dures, plants, great deal codes and more. When evaluating processes, it is very vital
to compare common causes along with the unique root causes of the variant. Special
sources of variation show a process modification, which requires to be examined.
The need to accurately forecast demand is critical to the manufacturers. Analyzing
demand in real time is inefficient given that companies need to make decisions about
the demand ahead of time to complete a whole production cycle and deliver the end
product to the customers. With predictive analytics, it is feasible to not just boost
the manufacturing quality, increase return on investment tool and overall equip-
ment effectiveness (OEE) but also prepare for various needs throughout the business,
exceed the competition, and guarantee consumer safety.
Production ventures have process professionals, operational excellence teams, as
well as designers who are smart and capable with an intimate understanding of the
production procedure, yet they need easy and instinctive logical devices to pull the
value out of information. Path to supplying impactful data-driven production jobs is
loaded with possible obstructions and mistakes. By encouraging process designers
with advanced analytics tools, more production issues can be assessed by analyzing
the information. The fostering of big data, machine learning, robotics, artificial intel-
ligence (AI) and IIoT is greatly impacting the industry and company.
Simulation
Simulation has become a part of NPD across industrial sectors allowing the product
or component or total system habits to be discovered and also tested in a virtual
environment. Simulation has actually established a close relation with both the com-
puter system industry and product design processes; it also provides an inexpensive,
protected and fast evaluation tool. Finite element analysis (FEA) is the simulation of
a physical sensation utilizing a numerical and mathematical technique referred to as
the finite element method (FEM); advancement in computing, modern programming
language, visualization tools and graphics have actually had a significant influence on
the development of simulation innovation. Real-time simulation technology is made
use of today in different industrial sector applications such as manufacturing, energy,
power systems, industrial products, valves, pumps, automotive and aerospace. It is
well-established during product design and validation that using simulation methods
to manufacture shop floor such as installing new manufacturing centers, assembly
line and also procedures yield huge advantages.
Simulation assists product design group, and a large range of various digital ver-
sions of the item can be developed and examined, making simulation part of the
design process itself. Another benefit of simulation is the possibility of carrying out
screening remotely from any part of the globe, which has proved to be a blessing
during the COVID-19 pandemic. Simulation has become essential enabling the tech-
nology of Industry 4.0 in decision-making, design as well procedure, covering the
entire life cycle of a production system and also paving way for the development
and implementation of Industry 5.0 to increase the effectiveness, safety, security and
ecological demands. Simulation is the only way to attain the intricacy of modern-day
product design in control and to successfully make use of the possibilities offered
by a quickly implemented technology. On collaborating with AM, simulation makes
sure that the final component not only has the optimal form but can also be produced
specifically, cost-effectively with a high degree of consistency. Simulations on the
digital twin can provide other crucial product information such as the do’s and don’ts
for optimal efficiency, forecast important failings and maintain requirements.
Fifth Industrial Revolution

The future of the industries is all about progress. Industry 4.0 is still the most preferred
technology among the manufacturers. The manufacturers of small and medium sized
enterprises have either partially or completely incorporated Industry 3.0 and Industry
4.0, and are eager to introduce more technological improvements. Hot progression in
AI, robotics, ML, data analytics, among others, is causing the birth of the fifth indus-
trial revolution or Industry 5.0. It will be an AI transformation with other innovations
such as quantum computing and integrating people, process, machines and environ-
ment with each other. Robotics is becoming more vital as it can now be paired with
the human mind using advancement in AI. A strong need to increase the productivity
while not removing human employees from the manufacturing industry is imposing
new challenges on the global industrial economic situation. Industry 5.0 will integrate
humans and machines to exploit the human mental ability and creativity even better
and to improve the process performance by integrating process with smart systems.
Industry 4.0 Technological

Industry 5.0 innovation
All Industrial
sectors
Benefits
Human Intelligence
Collaborative robots, Zero waste

Generative design production,
Environment-friendly
ecosystem, Huge use of
renewable energy,
Artificial Intelligence, SMART future
4D Printing, Bionics
Technological
Innovation
Product
personalization
The Future
FIGURE 3.8 The future of the industrial economy.

40 Industry 5.0
Industry 5.0 integrates intelligent automation, gadgets and systems at the work envi-
ronment to increase cooperation along with collaboration between people, process,
robots and shop floor machines. It assists highly skilled employees to lead smart devices
and robots to work far better. Economy and environment might see significant influ-
ences because of reduced waste product as manufacturing enterprises target zero-waste
production, lowering material and waste management costs. In regard to the social
environment, Industry 5.0 will certainly lay greater emphasis on the human aspect of
manufacturing, whereas Industry 4.0 concentrated only on the technology innovation.
One real-world instance is used by FANUC, a Japanese robotics business that’s a pio-
neer in lights-out production or dark factories they’re geared up with completely auto-
mated systems that can function in the dark without human guidance.
(Wheeler, 2015)
Connecting the virtual and physical worlds is the main criterion for the manufac-
turers to examine data, keep track of the manufacturing process, handle risks and
reduce downtime; all achieved by simulations with the advent of digital twins. With
the current innovations in large data handling and AI system, it is currently possible
to create a lot more sensible models depicting various operating circumstances and
also characteristics of a process. While representing unpredictability in the process,
digital twins offer an immense possibility by enabling reduced wastefulness by col-
laborating with the system. Industry 5.0 will bring unmatched challenges in the field
of human-machine interaction as it will certainly place machines extremely close to
the day-to-day life of any human.
Industry 5.0 uses the innovation established in Industry 4.0. Enabled by inno-
vations and by placing human beings back at the center of industrial production,
devices will normally perform the tasks besides being helped by cobots. Industry 5.0
is not just providing consumers the product they desire today but also accomplishes
tasks that skyrocket to new elevations and also are much more purposeful than they
actually have been in more than a century.
Collaborative Robots
Collaborative robots, called as cobots, are a new incarnation of a manufacturing bot
designed to work together with human beings as opposed to in their own area. Cobots
are experiencing rapid market development in industrial automation. These are cre-
ated to function flawlessly, together with human workers. Unlike traditional indus-
trial robots that might hurt a person in their vicinity, collaborative robots make use
of sophisticated aesthetic technology and are geared up with sophisticated sensing
units that allow them to identify individuals and change their task as well. Among
the greatest safety function of cobots is their force-limited joints, which are made to
sense forces as a result of impact and swiftly respond. Cobots are beneficial to small
and medium manufacturing enterprises due to their cost, versatility and flexibility.
Cobots are gaining popularity due to the fact that sensors and computer technology
have actually come to be so inexpensive that they are driving down the cost of robots.
Cobots are also easier to train and deploy than the massive industrial robots. Cobots
can be utilized is in every industrial manufacturing process from fabrication and
product packaging to CNC machining, molding, testing, quality assurance and so on.
Cobots will not replace human employees, rather they are going to work along with
them, accomplishing repeated jobs, which will certainly free workers to pursue other
tasks. Let us have a quick look on the evolution of cobots.
Robots were considered as machines of the future in the early 1980s; manufac-
turers began pressing the frontier onward to sustain industrial growth and achieve
greater production competitiveness by incorporating advanced sensing units and pri-
mary machine vision systems. Like all advanced modern technologies, cobots were
initially met with substantial hesitation by the production industry; one such dif-
ficulty was the requirement for fine dexterity and safety. In the early 2000s, growth
in industrial robotics was greatly driven by innovations in software application in
addition to emerging fields, such as ML and AI. This advanced the frontier of what
robots can do giving them the capacity to find out, boost, make decisions quickly to
prevent challenges without quitting the production operating at full speed and with-
out any assistance from humans. The initial cobot that can safely operate along with
staff members, getting rid of the need for safety caging or secure fencing, was intro-
duced by Universal Robots in 2008. Cobots developed for various applications still
call for special safety and security requirements as described by ISO safety require-
ments and qualifications (ISO 10218). With considerably reduced costs, cobots were
a lucrative automation option for small and medium sized manufacturers. In addition,
cobots broke all the norms for industrial robotics and consequently amassed wide-
spread attention in the manufacturing industry.
Manufacturers are in actual need of flexible options, cobot-based quality assur-
ance and evaluation systems that can transition between different final products in
very little time and end up being very attractive particularly to manufacturers aiming
Lean Circle
Dispensing, Polishing, With Machine vision

End Effecting task for Quality Inspection
Collaborative Robot
(Cobots)
Stacking Products Material handling ,

Automatically Pick and Place
Automation of Machine Tending

Product Assembly
Packing and Packaging
FIGURE 3.9 Applications of cobots.

42 Industry 5.0
to satisfy the quality control demands of high-mix, low-volume manufacturing oper-

ations. It is necessary for the manufacturer to do some research first, to comprehend
their business need, to access the investing capability in as well as understand the
innovation they are looking for. Cobots uses smart innovation, with downloadable
applications that make it very easy for someone with little or no experience to create
a collection of commands for their bots with just a few taps from their tablet, com-
puter or smart device. With the market’s value continuing to rise, cobots might soon
come a staple in every industrial sector manufacturing ecosystem.
Artificial Intelligence
AI provides the machine the ability to execute a task and reduce human effort with
the help of tools and also techniques that were created to provide the machine with
the potential to achieve tasks without human interference. AI is a modern technol-
ogy that can solve a great deal of business or personal activities that need decision-
making, intricate reasoning and knowledge. AI is a lasting technological development
of the future industrial economy. AI is the simulation of all-natural knowledge in
machines that are configured to discover and imitate the actions of humans. AI sys-
tems today primarily consist of neural networks that are educated with the help of
machine learning as well as deep learning. Virtually, AI systems need to first get
the necessary understanding to function. It does not matter whether it is images,
texts, language or any kind of data. It is vital that the training data record be refined
digitally. AI has acquired thrust; prominent application providers have actually suc-
ceeded in developing conventional software applications to create much more alter-
native platforms as well as options that far better automate business intelligence and
analytics procedures.
The advent of the industrial revolutions opened engendered many technological
innovations that opened the path to digital transformation across the different indus-
trial sectors. Hundreds of variables impact the production process, as data generating
from the shop floor machines are a perfect input for AI and machine learning. The
most up-to-the-minute term among the technology tycoons across different industrial
sectors is the industrial transformation powered by AI. In the production area, there
are digital twins of certain equipment properties, entire machines and components.
Because of the shift toward personalization in consumer demand, manufacturers need
to take advantage of digital twins to create numerous permutations of the final prod-
uct. AI aids the maintenance groups to identify potential downtime and accidents by
assessing the sensor data attached to the shop floor machines. Industrial robots check
thier own accuracy and also performance besides training themselves to improve their
use of AI. Cobots utilize machine vision to work securely alongside human workers.
Google utilizes AI in its data centers to enhance energy performance. AI aids to
transform manufacturing by minimizing its environmental impact. Chatbot is an addi-
tional basic AI application that most of the online business portals do have, and pres-
ently, it uses augmented reality too. Chatbot takes advantage of NLP to assess text fields
in studies and performs evaluations to reveal insights thereby boosting client satisfac-
tion and effectiveness. AI in the medium domain helps in discovering brand-new drugs
based on previous information and medical knowledge; it assists in reducing the cost of
research and development and delivers better result and performance. Integrating Food
and Drug Administration (FDA) information, AI helps in transform medicine discov-

ery by locating medicines in the market which are FDA approved or rejected.
AI chatbots to improve providing firm details on their official webpage. Using AI will
absolutely be important for SMEs; nevertheless, business proprietor will absolutely
need being future targeted and additionally prepared to touch the next edge with the
most up to date modern innovation.
(Adam et al., 2021)
AI assists manufacturing organizations, NPD team to make products utilizing gen-

erative design approach. Technology is transforming the means product designers
design the smart products of the future. A designer inputs the design objective
right into generative design algorithms, which explore all the possible permutations
of an option as well as generate design alternatives. Ultimately, it uses machine
learning to check each iteration and also surpass it. Application of this innova-
tion aids in discovering distinct means to reimagine parts across industrial sectors
while building products. In words of a product design engineer, “CAD applications
that autonomously produce a number of design options provided a set number of
constraints support, freeing product designers for other tasks, and on conclusion,
the designer is provided the option to choose which generated design they want to
check out more completely.”
As modern technology grows, AI is more easily available for manufacturing
industries, which are eager to accept new innovations. AI adoption in manufactur-
ing industies enables them to make quick, data-driven choices, enhance production
procedures, minimize functional prices and besides improve presentation to the cli-
ents. This does not suggest that production will be controlled by the AI powered
machines; AI powered machines exist merely to assist human work and can never
substitute human intelligence or man’s innate ability to adapt to unexpected transfor-
mation with the arrival of Industry 4.0 and later Industry 5.0.
4D Printing
4D printing emerging technology that incorporates 3D printing strategies with high-
level product science, engineering and software program. It makes use of liquid
crystal elastomers, shape-memory polymers and hydrogel, which are capable of mod-
ifying the physical and thermomechanical shapes in a programmable method based
on customer input or independent picking up. The technology is still in research.
Basically, 4D printing is an improvement on 3D printing wherein the printed items
transform shape post-production. A trigger might be water, warmth, wind and other
types of energy. Lowered expenses, enhanced software application designs and vari-
ety of printable materials have led to the development of a new modern technology
called 4D printing.
NASA’s Jet propulsion Lab has actually developed associate degree flexible steel mate-
rial that could be used for big antennas, to protect a ballistic capsule from meteorites,
in cosmonaut spacesuits, as well for capturing things on the surface.
(Landau, 2017)
44 Industry 5.0
4D printing is strongly influenced by the concept of self-assembly, a concept com-

monly utilized in nanotechnology. The key distinction is that 4D printed things
change their form with time as soon as they are published, whereas 3D published
products retain the same, fixed form, and in regard to material, it utilizes specially
designed “smart” materials that have several commercial properties that can be
transformed by outside triggers. Industry 5.0 inspires 4D printing because it will
certainly assist in focussing on product designing, as opposed to the manufacturing
process. The freedom of designing will certainly lead to the development of prod-
ucts, which are extra bespoke and unique.
CHALLENGES OF INDUSTRY 5.0

Manufacturers are still actively developing approaches for interconnecting new
modern technologies to enhance effectiveness above and beyond performance. The
directing principle behind Industry 4.0, the following stage of industrialization, is
already upon lots of manufacturers across the globe. As a result of a higher level of
automation in the industries, the existing business strategy and organization models
have to be modified and tailored to meet the demands of Industry 5.0. As a result of
mass customization, the company method will be concentrating much more on client-
centric operations. Organization techniques in Industry 5.0 demand higher degree of
dynamism to survive the competition due to differential customer preferences.
Client’s bias changes with time, and also, it is tough to transform business meth-
ods and also organization designs often. Smart manufacturing system along with
smart materials requires higher autonomy and also sociality capabilities as crucial
factors of self-organized systems. Working along with robots sounds fantastic, but
employees will have to find out how to work together with a smart machine. Beyond
the soft skills required, technological skills will certainly also be an issue. Industry
5.0 rollout is rigid due to lack of freedom in the present systems such as incorpo-
rated choice making.
BENEFITS OF INDUSTRY 5.0

Client satisfaction, as one of the major aspects of industry development, ensures
the positioning of products. Customers can mention their preferences in the design
phase and the production line can incorporate the specified preferences, with no
costs included. Industry 5.0 provides the NPD team the capacity to automate manu-
facturing, to obtain the real-time data for the analysis and also use that data in
the design process. The digital transformation of Industry 4.0 means smart manu-
facturing facilities with devices linked to the Internet. Manufacturing enterprises
produce, accumulate and also analyze information throughout the supply chain to
determine methods to drive quality improvement, process optimization, expense
reduction and also compliance. Industry 5.0 will incorporate the precision along
with the rate of industrial automation with the crucial thinking of human intel-
ligence. It adds durable and lasting policies, where even a minimal generation of
waste become important, cross-cutting procedures and makes the organization
extra effective and environment-friendly.
SUMMARY
Technology-driven transformation requires the appropriate organization culture and
the management executives to function appropriately. Modern technology alone is
not enough to drive the transformation; business leaders need to engage with their
workers to encourage understanding and acclimatization. Manufacturing industries
that take care to foster the appropriate culture around these new technologies will
be the ones with a competitive advantage, improving their existing business models,
developing new possibilities, while drawing in and also retaining brand-new skill.
Strategic investments continue to be vital for every manufacturing organization’s
ongoing development. Even if different aggregating techniques in varied opera-
tions can be come complex, the process aids manufacturers see high returns in an
increasingly competitive environment. This is really a future that provides value to
the manufacturing. A key aspect in improving business performance is possesing the
most efficient processes and the most effective people, focusing on our client’s out-
comes and using cutting-edge technology to identify areas for improvement to lever-
age engineering process effectiveness, through manufacturing effectiveness, across
different levels of the enterprises.
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4 Transformation in
Automotive Sector
Worldwide competitors, rapidly changing technologies, lowered product life
cycle, price reduction, high-quality products and demanding end customers are
several of the elements that have actually made manufacturing enterprises to
search for new techniques for establishing new product development. One of the
most significant inventions the world has ever witnessed is the automotive sector.
Manufacturing sector and automotive sector were strongly linked throughout the
twentieth century, and such ties will most likely remain pertinent in the future too.
The automotive sector includes not just vehicle manufacturing, but also compo-
nents and parts that are required to assemble a single vehicle; besides, a number
of sectors are associated with their manufacturing, such as steel, glass, plastic,
rubber, fabric and electronic devices. Currently, automotive sector is undergo-
ing massive technological innovation, from appearance to speed and advanced
capabilities; the automobile of today is smart and extra power effective besides
continuously evolving.
The path breaking technological development made in the automotive market
was the introduction of full-blown automation, a process combining precision, stan-
dardization, interchangeability, synchronization, as well as connection. The evolv-
ing digital transformation of product lifecycle expectations and the need for new
cutting-edge solutions will certainly influence all elements of the industry. The
industry is reaching an inflection factor in which electronics and software applica-
tion will displace mechanical equipment as the most vital components. The influ-
ences of automotive, technical and market fads are not restricted to the design and
manufacturing alone. This will have significant repercussions in the automotive
sector; they drive essential modifications in business models and functional frame-
works as significant industry transformers.
Automotive market is among the leaders of the fourth industrial revolution; how-
ever, there is a huge void between the original equipment manufacturer and dis-
crete manufacturers comprises SMEs, a lot more prevalent of Tier 1 suppliers and
Tier 2 suppliers. Quick technological growths resulting in improvements in design
and manufacturing, boosts in electronic driving systems, altering customer choices,
expanding concern about sustainability and regulative stress and measures to trans-
form the frameworks and developments in batteries have actually brought about sub-
stantial price reductions opening up great deals of possibilities for electric vehicles
(EV) manufacturing in addition to its facilities.
Automobiles have and always will be an important part of human daily living.
Tracking the advancement of the vehicle and its parts from its basic phase to its
present degree of luxury raises some inquiries, such as: What will the future hold
for passenger vehicles? What will be the capabilities of the automotive industry with
DOI: 10.1201/9781003190677-4 47
48 Industry 5.0
industrial transformation? Will factories in the future have the ability to operate on
a combination of machine intelligence and human intelligence? Having such sophis-
ticated modern technology, how will the growth be? Let us go further to touch base
few areas.
PROCESS REVOLUTIONS
The growth of automotive products has certain properties such as managing com-
plexity, traceability, awareness of the standing of information, trust in understanding,
dependability, vast use distributors, severe competitors, high development price, long
lead times, high degree of expertise strength, quickly changing technologies and also
the inherent dangers. The emphasis is on creating an item that meets the standards of
a premium client, so that the item can end up being a success on the market. SMEs/
OEMs have to attain success through carefully implemented new product develop-
ment process; it is a vital procedure for the success and survival of companies in the
automotive sectors. NPD process includes all the tasks from the approval of a sug-
gestion or a concept for a new product, to the realization of the product during the
manufacturing stage and its introduction into the marketplace. Generally, the NPD
procedure comprises different stages till the product is released such as planning,
product and process design and development along with procedure endorsement.
To make NPD effective, there needs to be a synchronization between the produc-
tion, engineering, research and development, advertising and marketing, finance and
purchasing departments. The difficulty lies in developing a procedure for successful
product innovation, where new product jobs can move quickly and also effectively
and efficiently from the concept stage to a successful launch the process of develop-
ment from the preliminary idea to the final authorization of the finished design spans
a period of years in which the design group jointly produces the end product informa-
tion. Quality function deployment (QFD) is utilized to convert client demands into
product and process design needs and identify the technical demands that need urgent
improvement, as it entails not just the customers but additionally the competitors.
The main challenge of the automotive industry for both the component supplier
and OEM is concentrating on the quality per cost ratio of the product manufactured.
Customer expectations are constantly transforming; so, automotive manufacturers
need to pursue continuous renovation, to make sure that errors can be avoided. So,
quality assurance makes certain that each item leaving the factory is of the high-
est quality meeting the consumer expectation. One international quality standard
that is endorsed by many nations and automotive manufacturers is the IATF 16949
Technical Specification. IATF 16949 helps manufacturers to improve their effec-
tiveness, performance efficiency, flexibility and safety throughout the supply chain.
It provides a framework for accomplishing the finest quality practice by an automotive
manufacturer, from design (product and process) till the production of the end prod-
uct delivered to the customer. Quality tools that any automotive center can make use
of to boost their quality assurance strategy that supports IATF 16949 are advanced
product quality planning (APQP), failure mode and effects analysis (FMEA), SPC,
production part approval process (PPAP) and measurement system analysis (MSA).
Client positioning, creative thinking and also development are important variables
Transformation in Automotive Sector 49
that affect the product growth process and are closely interconnected with high qual-
ity in the NPD process.
There are a few quality methodologies followed in different regions across the
globe, which are as follows.
Six Sigma
Six Sigma methodology is a business performance enhancement method (instituted by
Motorola), which intends to reduce the variety of errors as well as defects to as low as
feasible per million opportunities. It contains Define–Measure–Analyze–Improve–
Control (DMAIC) and Define–Measure–Analyze–Design–Verify (DMADV)
methods that eliminate defects from a process. Six Sigma DMAIC approach in an
automotive sector supplies a framework to determine, measure and remove resources
of variation in an operational procedure, as well as optimize the problem variables,
improve sustainable efficiency via process return with well-performed control strate-
gies. Six Sigma DMADV method in an automotive industry provides a framework to
create new a defect-free product and process to meet critical to quality (CTQ) aspects
that will certainly assure client satisfaction. Design process is one of the costliest
and also time-consuming phases; countless modifications following late detection
of product design errors are significant troubles that one comes across throughout
the automotive component and automobile perception phase. So, when dealing with
physical mock-ups, frequent reverting to previous decisions and limitless modifica-
tions the overall task expense is significantly elevated. Identify, Design, Optimize and
Verify (IDOV) is a phase process utilized by design by the Six Sigma (DFSS) team
for designing products and services to meet Six Sigma standards.
Toyota Production System

Waste can materialize as excess supply, supplementary handling actions, and mal-
functioning items, to name a few circumstances. All these “waste” elements combine
with each other to produce more waste, ultimately influencing the administration of
the automotive enterprise itself. The Toyota Production System (TPS) was developed
by Toyota Motor corporation based on two concepts: “jidoka” (automation with a
human touch), as when an issue takes place, the equipment stops instantly, avoiding
defective products from being produced; and the JIT principle, in which each pro-
cedure produces just what is required for the following process in a continual flow.
Through the repetition of TPS process, shop floor machines end up being less com-
plex and more economical, as maintenance becomes less time-consuming and much
less pricey, making it possible for the development of basic, slim, versatile lines that
are adaptable to fluctuations in manufacturing quantity.
Lean Manufacturing
Lean manufacturing is a technique that enhances the process with continuous
improvement (kaizen) as well as elimination of waste. Lean principles have actually
revolutionized the automotive market, permitting them to reduce costs and improve
50 Industry 5.0
their performance. Lean manufacturing has migrated to a more comprehensive area

of implementation called lean management. It is a common process administration
viewpoint derived mainly from the TPS. Lean manufacturing deals with a tried
and tested approach to get rid of non-value-added activities and also waste from
the enterprise process. It concentrates on lessening the human initiative, production
room, financial investment in shop floor machines and reducing the engineering time
to develop a new product. Value stream mapping (VSM) enables manufacturers to
develop a strong application strategy that will maximize the available resources. For
a lean manufacturing journey, VSM functions as the launching pad to start determin-
ing the best ways to improve their process. The goal of VSM is to recognize, demon-
strate and lower waste at the same time, highlighting the chances for renovation that
will significantly affect the total manufacturing system.
Truth for SMEs is that, as a result of the resource constraints, it is particularly crucial
that management executives are the ones to have extensive understanding of the lean to
enjoy its benefits. Lean calls for dedication and also the involvement of everyone within
the SME. It is typically extremely simple to function around the principles of lean to
hit short-term targets.
(Alkhoraif et al., 2018)
SMEs performing lean usually have a framework and easy systems, which promote ver-
satility to continuously evolve as well as disseminate information. Lean iceberg models
discuss that the execution of lean tools and procedures requires unnoticeable compo-
nents of determined positioning, management and additionally involvement. The stress
to fulfill the demand must be carefully maintained by retaining and even improving the
quality. This is where lean manufacturing concepts come to play. With the implemeta-
tion of Industry 4.0 and IIoT, lean goals will be completed a lot more immediately.
Lean principles are incorporated with less side innovations that make it feasible for
constant, real-time surveillance, quicker decision-making, boosted effectiveness, along
with the leanest procedures feasible. Lean is a journey not a final boundary.
World-Class Manufacturing
World-class manufacturing (WCM) is the ideology of being the best, the fastest and
also the cheapest manufacturer of a product and service. Fiat Group specifies WCM
as a structured over and above integrated manufacturing system that includes all the
procedures of the factory, the safety atmosphere, from upkeep to logistics and simi-
larly high quality. WCM suggests consistent improvement of products, process and
solution to remain an industry leader and also supply the most effective choice for cli-
ents, regardless of where they are in the procedure. WCM calls for all decisions to be
made based on unbiased measured information and its analysis. It aligns people, pro-
cess and also innovation capacities to develop a culture of continual enhancement, tar-
geting zero losses, client cases, quality flaws, device malfunction as well as accidents.
Quality Control performed across the supply chain as modifications in manufac-
turing procedures, consumer demands and disruptive trends all affect the automotive
supply chain network for resources, parts and finished components. Vendor develop-
ment is indeed an essential role, streamlining the flow of components in between
suppliers and manufacturers in automotive NPD and NPI processes. Now, there will/
might be questions that arise in the minds of SMEs: Which above-mentioned method
should be used to improve the process? SMEs have much less experience with busi-
ness enhancement approaches; it is far better to go ahead with the stepping stone
approach. Process designers evaluate and create procedures to increase performance
and also range their business services. The decision to choose among the techniques
does not need to be puristic. Consider the requirements from customer together with
the changing demands as the baseline, which is the starting point to convert exact
customer demands into products, by maintaining the quality, throughout the product
development process. A complete and excellent execution of one technique is not the
goal. Be versatile and continue to be to think out of the box to carry out an improve-
ment technique, if necessity demands. It is only the outcome that matters, which is
of far more worth to the service and consumers. With the industrial transformation
and the arrival of innovative manufacturers, the early idea of quality transformation
was previously considered unpredictable as well as largely identified by the skills of
individuals. The underlying success of the continuous improvement technique lies
with leadership support, involvement, tactical focus and also execution.
Technical or industrial technology is used to describe a new breakthrough in a
procedure or a manufacturing method or a unique product, and it is utilized exten-
sively by economists. The products are configurable with set of services to addition-
ally improve the product value and its usage. The challenge in designing a system
of automation components of lasting worth lies in understanding the possible needs
of the future. A specific synchronicity is called for in order to align product devel-
opment with automation through the production operation. Enterprises requires to
take on an electronic improvement effort with the goal of tying in all the relevant
silo systems to develop a single collection of relevant information that flows via an
ecosystem of seamless data connection, obtainable to all service partners, both inter-
nal and external, called the digital thread. It aids in upstream and downstream work
with the exact same product definition information that is trustworthy and work-
able, consequently, delivering high-quality products avoiding several interpretations
of the same information enabling interaction of engineering modifications, making
quicker decisions and also executing them easily as it is readily available to all cross-
functional teams of NPD/NPI in the item supply chain. Increased collaborations
between product engineers and production engineers assist in designing manufactur-
ing procedures. By linking smart items, manufacturers can collect feedback from
the product’s field performance and use; thus, boosting product design can produce
brand-new organization chances for customers.
BUSINESS NECESSITY FOR PROCESS TRANSFORMATION

In the industrial world, technical innovation is rapidly changing, and the future is not
certain; correspondingly, it will be important for automotive businesses to swiftly
maximize brand-new possibilities and benefit from this disruptive development.
Process transformation is the buzzword being talked about in every conference room
of SME (Tier 1 or Tier 2 suppliers) and OEM. Automotive suppliers and OEMs are
called for to prepare for a major change throughout the whole value chain, as a result
52 Industry 5.0
of process transformation in the production as well as in the supply chain process.

Process change is to attain essential objectives such as using technology for much
better service outcomes and optimize company processes with electronic innovation.
There is no single dimension that fits every supplier and OEM for effective process
transformation. Every supplier and OEM of automotive industry is different, with
their very own method of doing things and abilities. It is understanding what those
strengths are and how to use them that makes the difference between the actual
transformation and the unrealized aspiration.
Any technological and process development is bound to have a solid effect on the
established standards starting with product development, manufacturing, distribu-
tion and the everyday use by the end consumer. Process transformation that func-
tions well for an automotive business can bring substantial, favorable adjustments
in operations, waste reduction, expense reduction, high-quality products and also
go-to-market strategies. It usually involves an assessment of the actions called for
to accomplish a particular goal in an initiative to remove non-value-added steps and
automate as many actions as feasible. Enhancing a consumer’s journey requires the
automotive industry to recognize every modern technology, process, ability along
with the transition required to provide a terrific experience. Sustaining in the digital,
smart connected age requires predictive intelligence and ideal timing to respond to
the tranformations in the industrial economy.
First and foremost is to focus on the existing abilities that have a direct effect on
the success of the process transformation. The aim must be to make the necessary
changes to the procedures, individualsand technology to align the business with the
organization’s strategy and vision. Almost, it is the procedure of end-to-end customer
experience optimization, functional flexibility and technology development that are
key drivers of organization digital transformation model which opens up new income
and value. Automation has proven to be an efficient transformation tool to boost
productivity in production. The incredible progress in robotics, artificial intelligence
and machine learning, and so on will assist SMEs to OEMs of automotive industry
to become much more affordable with design and manufacturing cycle time reduc-
tion. With several new modern technology innovations and market shifts striking the
industry at the same time, automotive discrete suppliers are facing one of the most
difficult settings of the last century. Are automotive components manufacturers or
OEMs prepared for today’s auto industry’s evolution patterns? If so, process transfor-
mation should be considered as a long-term journey that starts with a few concerns
that need to be clarified before commencing the initiative.
PROCESS TRANSFORMATION REVOLUTIONS

Digitized technologies in the production are changing every department in the auto-
motive manufacturing, from product development to manufacturing to sales through
services. The fast pace of process change is transforming the component hardware-
driven automobile sector to a software program and solutions-focused sector, accel-
erated by the customer’s advancing expectations and needs for new digital innovative
services in the era of Industry 4.0. The quick growth of robots, data analytics and also
the rise in the use of the IIoT allowed digital connection by linking the firm’s man-
agement and process with the customers. Awareness of technological innovation and
its effect on the business model needs to be high; therefore, a great deal of effort and
time has to be invested in bringing this bent on the brand-new environment, not sim-
ply from a technological perspective but also regarding the security process effects
of the digital and ingenious modern technologies. To attain functional excellence
and strategic improvements, automotive leaders need to touch base transforming dif-
ferent service procedures within their venture by looking past modern technologies.
Few areas of process transformation in the automotive sector are discussed here,
which will/can assist SMEs and OEMs.
High competition in the automotive industry pressures manufacturing enterprises
to invest in better equipment and smarter options to boost the high quality of the new
product without jeopardizing the timing. The mainstay of modern technology that
develops the base for automotive sector is high-performance computing that com-
prises of CAx, PLM, ERP and MES.
Implementing PLM for SMEs

Products are the lifelines of all automotive sectors in addition to becoming more advanced
and smarter. CAD data give product details for all product manufacturing SMEs and
OEMs. To maintain information efficiently, these CAD details need to be shown to all
the CFT of the product design and development. Originally founded as engineering data
management, these systems managed CAD data and subsequently developed into PDM
systems taking care of CAD documents, bills of materials, variations and also revision
control. PLM manages all aspects of the product life cycle, from concept design to prod-
uct retirement, collaborating with extended enterprises across the globe.
Business Challenge
SMEs face the same challenges in handling 3D CAD data that the OEMs manage.
Engineers and designers attempt multiple product design alternatives, to find the best
solution. To manage the complexity, they need to track what they designed yester-
day and the week before, in addition to what they wish to retain, replace or review
and approve progression; thus, the process gets extremely unpleasant for the product
development team.
Precondition
CAD application for modeling product design comprises of design data as well the
details about the product such as part number, type of the part, customer and revision
as per the customer requirement along with the NPD/NPI program.
Approach
Essential components of the PDM innovation and execution process need few dedi-
cations as it involves the entire CFT within the enterprise, the vision and the man-
agement strategies to roll out. Begin with, two crucial functions are configuration
management and process management. The major task for the configuration manage-
ment is to keep track of the right set of documents for each version of an item. Process
management is used to automate numerous procedures in the enterprise. Leveraging
a protected vault extends the access to the 3D CAD environment along with its asso-
ciated data, for all the participants from engineering to production. This makes it
54 Industry 5.0
Design Data Management
Vault E-BOM, Product Structure
members of NPD/NPI
Accessible to Design
Product Data
Management
Design
Version and Revision
Engineer
Control
Review and Approval

Process
CAD Application Promotion – Maturity of

Data
FIGURE 4.1 Implementing PDM: Foundation of PLM.
possible for every person associated with the tasks to share details and team up on
designs, while automatically safeguarding the product copyright with the automated
variation and revision control.
Result
PDM as the core of PLM provides complete configuration control of the product
data from all phases of development, from initial idea, through design, development
and manufacturing. It provides the product development team the path to access all
product-related details on the various restraints and also demands at the different
phases of the product life cycle. PDM and PLM are currently driven primarily by
cloud computing technology. Cloud is a perfect standard to share data. It speeds up
the moment of implementation, gives adaptability and also decreases the overall cost
of ownership. Cloud PLM boosts advancement and flexibility across the community,
making it possible for the extended enterprise. SMEs are anticipated to constantly
produce faster besides reinventing products, while boosting sustainability in this
Industry 4.0. It also decreases both the cost and application of PLM as well as paves
the path to digitalization. SMEs require to begin their process journey with PDM and
then go on to PLM supporting the NPD process.
Implementing Process Control System (PLC, SCADA) for SMEs

Automation has taken over the assembly line of automotive manufacturing, which
includes four process, namely welding, stamping, painting and setting up. A service
technician remains in place to monitor the PLC to discover especially what is malfunc-
tioning and proceed to take the required action. PLCs have contribute a lot to process
transformation in the production shop floor and correspondingly play a major role
in industrial companies, especially for small and medium sized manufacturers plan-
ning to adopt Industry 3.0. MES integrates multiple control systems that supply visual
monitoring applications; one of which is the application of SCADA to collect real-time
information that can effectively regulate and keep an eye on industrial machines along
with the manufacturing processes. Also, it forms the basis process drive of IIoT.
Business Challenge
A significant challenge encountered by a majority of the SMEs and OEMs is the dif-
ficulty in connecting numerous shop floor machines along with machine tools that
do specialized actions, share information among different devices and equipment in
real-time and assembling it into a legible and actionable task influencing elements of
the automotive production process. Process control automation is rather remarkable
to look at. Many of today’s products are made with the aid of a closed-loop signal
chain, with less intervention from the operators. The manufacturing floor requires
accuracy and a limited number of failings, so the manufacturing process needs to be
frequently measured and also regulated.
Precondition
Hardware – PLC, Software – SCADA, Human–machine interface (HMI), DCS,
MES, Shop floor machines, Sensors, Actuators.
Approach
PLC’s features are separated right into three major classifications as inputs, outcomes
as well as the CPU. Innovation in industrial automation still processes with some types
of hand-operated controls, which does not always guarantee optimal performance.
By using control tools, it is possible to optimize the procedures, provide a secure
and reliable operation with data offered much more quickly. PLC is an equipment
that gets information from connected sensors and input devices, processes the data,
and triggers outputs based on pre-programmed specifications. It records information
from the shop flooring by monitoring inputs that devices and machines are linked
to and by utilizing software program SCADA. The production line operator monitor
and regulate the PLC and record data, even from remote locations. Collaborating
SCADA, MES and HMI systems, together with an enterprise-wide solution, allows
manufacturers to see and control information on a PLC.
Result
The targets will be achievable by having PLC and SCADA and by establishing sig-
nificant rigid delivery routines, thereby increasing production, effectivity as well as
performance through the procedure of information technology systems monitoring
and industrial control devices.
Heat Treatment Process

While talking about the manufacturing process of the automotive components,
material plays a vital role, and how it is heat treated for strength and stability is a
must to go through. Despite the arrival of electric cars, heat treatment of vehicle
56 Industry 5.0
components remains to be existed. It plays a crucial role in product development

and sustaining new technologies. Advancement in heat treatment process across
various industrial sectors takes care of preservation of power inputs, concerns about
environment, utilizing standard materials in modern non-traditional ways and exe-
cuting value-added procedures to upgrade existing materials to meet a lot more
rigid guidelines, safety of human labours and customer demands. The introduc-
tion of lightweight aluminum alloy in the automobile body and structural parts has
caused extra obstacles for thermal processes and equipment that improve the com-
ponent strength and ductility characteristics. Correct control of distortion after ther-
mal treatment of powertrain elements in the automotive market is a vital action in
ensuring top notch componentsas well as to minimize hard machining procedures
in order to decrease overall production costs. There is an ever-increasing product
need for steel and aluminum materials with boosted mechanical and metallurgical
properties to fulfill the challenges of the automobile manufacturing procedures.
Below is the use case of SCADA used to improve safety, streamline and automate
heat treatment processes.
Business Challenges
The automation of heat treatment process has big application in automotive indus-
try. The majority of this process is carried out in hand-operated situations in SMEs.
The person needs to monitor the home heating chamber constantly and preserve the
temperature and time duration of heat applied in steel throughout the whole heat
treatment process.
Quality Control, Maintenance, Operator, Supervisor, Plant Manager Remote Dashboard

Control System
Adjusting HUB
Data and Control
Ethernet
Data Collection and Integration
Alarm Monitoring, HMI / SCADA Enterprise DB

Corrective
Maintenance DCS OPC Server
Monitor process and Reports

Quality Control PAC PLC Machines MES, ERP
RTU RTU
Industrial Enterprise
Automation Sensors, Actuators, Instruments Inputs, Manual Input
FIGURE 4.2 Shop floor process control automation.

Precondition
The important conditions for the heat treatment process are exact temperature level
control, accurate structure of the atmosphere and specific timings. High volume heat
treatment of material proceeds with continual heating process, and that the material
is constantly moving into and out of the heat chamber without actual start and stop
point at the same time.
Approach
SCADA provides heat treatment plants amazing abilities for remote operation and
surveillance of the heating systems with user-friendly online devices. It helps con-
trol processes and immediately accumulates information ensure that the systems are
running accurately, and every part of the process is accurately recorded. PLC helps
to regulate temperature settings, speed of the fan and so on. PLC helps to regulate
temperature settings, speed of the fan and so on, those at the entry and exit terminal
control, which includes the electric motors and hydraulic cylinders of the handling
equipment. SCADA ensures that there is power to allow different items to travel
through the workstations in various cycle series, while ensuring complete integrity
and compliance requirements set forth in widely used industry standards such as
AMS2750 in aerospace industry and CQI-9 in automotive industry.
Result
Diagnostics are made certain exact alarms that alert the operator or maintenance
worker right away to identify any anomaly and promptly secure the typical opera-
tions. PPAP can additionally be made use of to establish and record fixed heat treat-
ment procedures besides forcing the SME resources to demonstrate process capability
prior to introducing manufacturing. It ensures formal quality preparation and forces
vendors to report and document any kind of process adjustments, prevents the use of
non-conforming products, and reduces the possibility for guarantee claims.
Predictive Maintenance in Heat Treatment Process

Predictive maintenance of the heating process furnace will show whether particu-
lar maintenance activities are required, shifting from a timing-based maintenance
to a condition-based maintenance. The energy consumption is dependent on power
as well time. A lot of the industrial sectors are utilizing vacuum heating systems
as opposed to blast furnaces as they produce much less carbon dioxide, and it is
environment-friendly. IIoT assists to identify problems of any kind, be it part of the
system or the whole heating system, and anticipate malfunctions, thereby determin-
ing one of the most affordable times and approach for maintenance without the loss
of productivity. The integrity of devices being connected to a heat treatment device
has enhanced dramatically whereby the environment can stay clear of physical col-
lection of information by a service technician. Modernization of the heat treatment
shop floor is crucial to both success and survival of the industry. Predictive mainte-
nance technology is becoming a powerful tool for heat treatment in the automotive
sector for analyzing performance and effectiveness.
58 Industry 5.0
Past
Present Future
IIoT Platform –What is happening currently

What occurred What is most likely to occur
Real Time Control

Real Time Data
SPC Predictive Analytics

Collection
History
Data Analytics
Industrial Control
M2M
NDIR Gas sensor,
System
IR Sensor, Hydrogen Sensor Predictive

Action and
Maintenance
AI assisted Cobot
FIGURE 4.3 IIoT and cobot in heat treatment process.
Additive Manufacturing
Faster product advancement along with technological innovation is vital to an
enterprise’s success; rapid prototyping becomes one of the most essential elements
of new product development. Quick fabrication of physical models making use of
three-dimensional CAD data turns ingenious concepts right into effective end parts,
swiftly as well as efficiently. Product layouts, and prototyping procedures of build-
ing, assessing and fine-tuning, suit all significant stages of the design process. A pro-
totype is a preliminary variation of the end product; it is made use of to assess
the design, test the technology or assess the working principle, which subsequently
supplies item specifications for an actual working system. Rapid prototyping tool
for automotive parts design process has now advanced in the direction of additive
manufacturing (AM) or 3D printing, which is a game changer for OEM and SME
automotive component manufacturers.
Generating spare components is a classic example of 3D printing. Porsche supplies
parts for its vintage and out of production designs, using 3D and Ford incorporated
3D printing into their product design and development process, it creates 3D-printed
prototypes utilized for layout validation and also functional screening.
(Newsroom, 2018; Henry Ford, n.d.; Ford, n.d.)
AM enables quick prototyping in the pre-manufacturing stage. One of the most popu-
lar ways is to confirm a model from a small promptly published information to a high
detail major component ideal for efficiency validation. It reduces the cost involved
and also long lead time CNC production. The parts created by the 3D printer are
cheaper, and their in-house manufacturing time is much shorter. It aids designing in
the automotive industry enabling product developers to attempt several choices of

the very same information and iterations throughout the stages of NPD. 3D printed
parts are more ergonomic and yield higher operator interaction as comments can be
easily included into design models, all adding up to unmatched effectiveness levels.
Virtual Reality and Augment Reality

Automotive vehicle and component designers interact with the vehicle prototype to bet-
ter recognize communications between components and parts. Product design reviews
end up being more efficient, as virtual reality (VR) helps businesses to dramatically
decrease the number of models needed for the automobile promotion. Consequently,
the advent of VR and AR is the most promising innovation of Industry 4.0, which has
spread its arms in the automotive industry extensively. VR gives the opportunity to
gather all CFT of NPD/NPI and suppliers in the exact same virtual work space; thus,
it favors explanation of misunderstandings and brings about quicker and a lot more
reliable decision-making and offers broad capabilities for training engineers. AR is
obtaining traction quickly, driving value for the enterprise and the clients.
AR technology in an automobile is the motorist experience improvement, can be
discovered in the type of transparent display screen screens in windshield task more
details concerning surrounding environment, troubles, as well offering instantaneous
details on any kind of vital events, without sidetracking from driving.
(BMW UX, n.d.)
The exceptional thing about AR is that it enables users to connect with the real world
making use of technology-supported graphics. For things that can be quickly solved
without an auto mechanic, operators can provide this technology for self-service.
Quality Standards
The development of autonomous cars will change the means the automotive sector
operates. Large scale adoption of this modern technology is reliant on a significant,
however not impossible, change in perceptions. The difficulty for the automotive
market is the critical timing of investment according to transforming attitudes. The
potential to access new markets is not restricted to automobiles alone; moreover,
the worldwide need for vehicle parts is perpetually increasing. The changes present
distinct production obstacles to electronic manufacturing services (EMS) providers,
who serve automotive OEMs and their suppliers.
Considering the enhanced consumer satisfaction, safer products, improved per-
formances and also a raised bottom line, it is easy to see why the value of a quality
assurance system is growing in the automotive sector. Security is of highest impor-
tance, and, a top-quality monitoring system is a crucial means for vehicles along
with their parts to pass safety examinations and standards. Automotive products
need to fulfill conformity besides functional quality, making sure that industry ideal
practices are being followed across the enterprises. So, one such technique is IATF
16949, a globally acknowledged high-quality management standard, which provides
a framework for accomplishing the finest technique in an organization, touching all
60 Industry 5.0
areas from design through production of the end item and its components that enter
into the automotive supply chain. SMEs that lack the resources to address these pro-
gressing demands might require to utilize the quality assurance capabilities of their
bigger business partners, consisting of distributors and examination subcontractors.
It means that SMEs need to have their community partners provide specific contrac-
tual guarantees to the customers. SMEs also need to take actions with their mostly
contracted out supply chain to ensure continuity of supply, second-source needs and
also conformity with hazardous substances and ethical sourcing laws. OEMs have
been understood to involve with SMEs while at the same time developing their very
own remedies, often learning from the SMEs at the same time.
Numerous complex products have flooded the automobile market as most auto-
mobiles are packed with every sensor, consumer electronic and infomercial option
feasible, for instance, the expanding number of chauffeur assistance systems required
to counter all the distractions created by the various other innovations in the cabin.
Product and process development in the automotive industry has actually been pro-
gressing impressively. An automotive supplier to OEMs accomplishing these market
requirements shows that it can deliver higher product top quality at lower failure
rates. One such industry standard is automotive software performance improve-
ment and capability determination (ASPICE). It offers the framework for specifying,
executing and assessing the process required for system growth focused on soft-
ware application and also system components in the automotive industry. During
the supplier option, an OEM can utilize the ASPICE structure to examine the ability
and quality of the distributor. On the other hand, ASPICE can prove to be an ideal
structure for the suppliers to take their existing high quality a few notches greater.
This includes the support, that Tier 1 and Tier 2 suppliers can offer their products,
manifesting how reliable and consistent their interior processes are.
The progression from the third industrial transformation to the fourth followed by
the from fifth industrial transformation in the direction of digitization consists of auto-
mation, robotics, cobots, artificial intelligence, machine learning system. It is crucial
for the automotive SMEs and OEMs to rapidly adapt to these radical transformations in
the market to top the competitive landscape. Organizations need to be developed to be
robust and also to deal well with the increasingly fast pace of process transformation.
BUSINESS CHALLENGES IN PROCESS TRANSFORMATION

Process transformation, automation and the introduction of new business mod-
els have changed the industrial sector in the last few years, and companies need
to adapt to the new ecosystem. Patterns such as enhanced connectivity, ecological
guidelines, IIoT, wireless services and client assumptions drive investments into pro-
cess improvement in the automotive industry. Process transformation efforts loop
technology-driven fads along with consumer demands to stay affordable in this smart
connected manufacturing world. Smart connected supply chains drive costs down,
involve the consumers better and also collect user data for a much better service. A
few of the challenges are to set manufacturers ‘cost planning and preparation, emis-
sion planning, accountancy, inventory monitoring besides manufacturing prepara-
tion. In the context of process transformation, these tasks become increasingly more
complicated due to the use of large amounts of information.
The common challenges of small and medium enterprises are lowered client buy-
ing power, limitations on communication, lacks of resources, cancellation of orders,
cash flow problems and also supply chain disturbance. To embrace the industrial
transformations (Industry 3.0 to 4.0 through 5.0), small and medium sized enterprises
should respond quickly and establish an overarching digitization strategy so as not
to be overwhelmed by the plethora of possibilities and need to become extra nimble,
quicker and also bolder. SMEs need some positioning along with a general under-
standing of the process transformation initially. Few SME’s that are not familiar with
technology struggle to understand what to digitalize, which technology to utilize,
exactly how to focus on objectives and which business changes (e.g., skills and also
functions) are required. It does not always have to be big and costly applications
that bring SMEs to achieve the goal. A lot of these buisness applications are cloud-
based and provides fourteen days to one month of trial version to play around, which
gives the sufficient for the SMEs to decide whether the corresponding application
fits their business process or not. The sooner the SMEs address the above challenges
the quicker they can reap the benefits and to position themselves better than their
competitors.
OEMs or large enterprises have a myriad of siloed systems including numerous
scraps of information regarding consumer interactions, but no clear way to pull them
together. One such means is to follow the path to success via the examination and dis-
cover technique, where new functions are being regularly added, assesed, modified
and trimmed, based upon individual comments and user data. The early identification
of emerging markets or technological gaps or the boosted visibility of rivals motivate
the enterprises to respond swiftly. They can also establishing processes designed
to generate profiles of prospective concepts for the future state of their transforma-
tion journey. Dedication and an adaptive mindset are called for in all levels within
internal divisions. Future development and vigor call for equivalent focus to various
metrics, consisting of client contentment, partnership growth, time-to-market tracks
for brand-new products as well as inner adjustment matters. One effective way is to
take a step back every couple of months and also assess how businesses are profitable
in this competitive market.
Overall, automotive manufacturers need to learn from modern technology trend-
setters and begin to digitize their whole manufacturing procedure. Some other perti-
nent challenges faced by the automobile industry are safety and security, conformity,
meeting customer requests and digital expectations, managing large data, working
with brand-new companion’s process improvement professional and developing
value chain impacting every facet of the automotive industry. OEMs are leading the
adoption of process transformation and ingenious innovations, whereas few SMEs
are at a nascent phase. Financial investment in automotive procedure change and
enterprise will need to stay focused on one of the most useful use cases with the
highest possible ROI. Any kind of transformation needs to start by basically ana-
lyzing and studying the attempted and evaluated business designs, procedures and
organizational structures. Based upon a convincing vision and a service technique
that is derived from that, the process transformation must then address an extensive
strategy, with sustainability as an essential component of the process transformation,
and a strategy that guarantees that innovation is being executed in such a way that it
supports business purposes.
62 Industry 5.0
BRIDGING PROCESS REVOLUTION TO

Industrial transformation’s true worth lies in ultimately shutting the void between
production and engineering. When products are updated, everything required for
manufacturing, from the production illustrations to the expense of materials, can
stream per plant. Having live manufacturing information come directly from the
design engineers will additionally cut short a great deal of the iteration and model
validation time. From product concept to end of life, the emphasis of SME and OEM
is to take care of product data securely, decision making and forecasts effectively.
The safety of the work environment can be enhanced by permitting a cobot to
manage hazardous jobs. Cobots with electronic vision camera use simple integration
for testing and quality check, ensuring the high quality of the end products identify-
ing defective components prior to they being sent out to the last assembly. Cobots are
progressively backed by artificial intelligence and machine learning technology that
let them do advanced tasks along with sharing the lessons discovered. Manufacturing
automation does not just include introducing brand-new modern technologies; also,
the existing automation system can be upgraded to be made smaller and getting new
controls becomes a lot more effective, efficient as well as attainable. Advancement of
smart products that contain useful components designed to react to specific external
environment along with the accessibility of 3D printing, set the stage for 4D printing.
4D printing technology in the automobile industry can bring about finishing that
adjusts to nature changing conditions. 4D printing innovation incorporated with
cobots enable them to print tailored reuse of automotive components.
With the help of AI, OEMs and SMEs can automate processes, equipment, devices,
labor demands, forecast needs, enhance inventories, logistics and monitoring. The
adoption of artificial intelligence innovation by the automobile industry has created
numerous partnerships between conventional component manufacturers, technol-
ogy giants and niche startups besides service providers. For OEMs, the efforts and
expenditures involved in embracing AI are worth it, and they are ready to take the
economic dangers. Suppliers can make use of AI-driven systems to create routines,
manage processes, allow robots to function securely alongside people (to an extent)
in the production line and also recognize issues in components. AI can additionally
function as an enabler to automate, accelerate and enhance the accuracy of the prod-
uct design and development processes. AI-powered hardware can visually inspect
and provide exceptional quality control on numerous items, such as machined parts,
painted vehicle bodies and distinctive steel surfaces. AI-powered innovation has
actually been utilized in an automated guided vehicle (AGV). Counting on artificial
intelligence without any human aid, AGVs recognize the crammed objects, readjust
their routes and also supply materials to numerous parts of automobile plants. Even
though difficulties still exist, such as the complexity of software growth, conformities
and laws, various fields within the automotive sector are already leveraging AI tech-
nology on top of seeing enhanced effectiveness and also optimization of procedures.
The largest drivers of change and development originate from using electronics,
information and communication technology in automobiles. Suppliers play substan-
tial roles in the design of systems, controlling of supply chains for manufacturing and
also assembling. The innovation of Industry 4.0 are installed in cars, and the relation-
ship between technology firms and automotive market manufacturers is additionally
going to undergo significant changeover.
SMEs are the foundation of industrial economy advancement. The most criti-
cal problems for SMEs are sustaining the high-quality and constantly striving to
improve, the extent and range. A few of the major variables responsible for this are
substantial hand-operated treatments in processes, interrupted flow of information
and also the absence of experienced manpower. The development of the automobile
sector has actually assisted in the development of a big environment of SMEs cater-
ing to the automotive sector, and their standards are lifted and quality increased. The
requirement of the hour is for SMEs to take the lead in adopting brand-new technolo-
gies and making them an indispensable part of their organization approaches. Those
that succeed in comprehending the power of digitalization and exploiting it across
their businesses will lead this new age of growth.
Leveraging Industry 4.0 technology for efficient real-time surveillance and
analysis is the real need in the smart connected manufacturing environment.
Manufacturing execution systems used in production, to track and also record the
transformation of basic materials to end items integrated with robotic automation
along with machine-to-machine (M2M) communications and enable real-time data
tracking and analysis abilities that include more agility to automobile production.
Tapping real-time information created from tasks on the shop floor, top quality and
manufacturing facility personnel can execute root cause analysis and make proce-
dure adjustments really promptly. Applying top quality methods and Industry 4.0
innovation facilitates quicker, real-time interaction and ensures constant interna-
tional operations that equate into enhanced regulative compliance. Providing high-
quality and absolutely no problem products is vital not only from the perceptive
of quality control but also from the safety point of view for automotive OEMs and
SME; this aslo translates right into a positive experience, the supreme standard for
consumer complete satisfaction.
With the arrival of Industry 5.0, production process within an automobile indus-
try could be considerably transformed with AI to ensure that human laborers are no
longer required to do the very same tasks. Likewise, manufacturers explore the use
of exoskeleton wearable industrial robots to protect human employees, making them
a great deal more powerful while keeping their mobility at maximum. Robotics and
cobots along with AI procedures eventually change the requirement for low-skill
workers, which naturally has the potential to retrain those employees for greater
level tasks. As manufacturing enterprises use IIoT in the form of advanced software
application that analyzes vital data, automotive manufacturers can to work toward
lean production purposes, thereby improving total manufacturing rate and procedure
quality. It is time for both discrete manufacturers and OEMS to embrace the journey
of Industry 3.0 along with Industry 4.0 through Industry 5.0 technological changes.
Automotive manufacturing businesses give a purposeful and special enhancement of
their operations by combining AR tools with advanced picture recognition modern
technologies, computing power, IoT/IIoT tools, and AI to develop really powerful
evaluating devices.
64 Industry 5.0
SUMMARY
Potential for industrial transformation in an automotive industry is substantial.
Man, machine and manufacturing procedures are smartly networked individual
products of top quality can be developed much more rapidly, and also expenses
can be made competitive. The industry of the future will allow transformation
at their origin to incorporate the consumer demand well in advance. It includes
change of manufacturing processes including smart tools, reduction of manual
labor, radical reduction in downtime and most significantly adaptable manufac-
turing systems. Because of the increasing demand for automation in factories,
the future will certainly have more affordable cobots, software and small-sized
workstations that are personalized. Therefore, not just the product but the devices
making the product can likewise be modular, which would certainly customize
itself based on the preferred product design change. Product design procedure in
the future will certainly boost the present quality system to respond to consum-
ers swiftly while maintaining the same level of quality and integrity. This will
certainly not just include research into sophisticated materials but also include the
processes that use them.
Industrial processes will certainly change as the future fads in the direction of
electric automobiles, and also, independent automobiles will additionally impact
production as well. The engine in the automobile is already being replaced by bat-
tery cells. This impacts the entire supply, and the process innovations in prod-
uct design and development, product distribution and logistics also get influenced.
Faster distributions come to be priority as customers strive for customizability and
extremely customized products of the future. As machines become smarter with
sensors, information collection and administration become an essential element of
Industry 4.0.
Automobile industry is facing essential process transformation: the electrifica-
tion of the powertrain, embracing the advancement of technology standards espe-
cially digitalization. Currently, most of the automotive manufacturing industries lie
in between the second and third to fourth generation of industrial transformation.
It indicates that although automotive manufacturers may have microprocessors,
robotics and also computerized systems doing the support, they additionally have
some type of manual work being done. It might entail people doing visual inspec-
tions on the product, product coordinators, logistics such as relocating containers
manually; besides the low quality of components boils down to the individuals
along with the absence of training in manual procedures. Therefore, automotive
manufacturers need to go completely computerized in their journey from Industry
3.0 to Industry 4.0, before starting the drive toward Industry 5.0. Many aspects of
the typical automotive sector are being influenced by the technological innovation;
rather than anxiety, the SMEs plan to lead them by developing automobile parts
that do not pollute, have zero emission, decrease waste and adhere to energy reli-
able processes that are crucial in this smart connected environment-friendly world.
It unlocks brand-new technologies that revolutionize automotive sectors and often
the culture itself.
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5 Transformation in
Hi-Tech Electronics
Industrial Sector
Electronics is one of the fastest developing, most innovative and the most affordable.
Electronics sector plays an incredibly significant role in modernization, and a terrific
emphasis on its advancement needs to be placed with the use of electronic technol-
ogy in all markets of the dynamic industrial economy. It is composed of enterprises
associated with the manufacture, design, development, assembly and maintenance
of electronic equipment and components. Electronic items array from discrete parts
such as integrated circuit, consumer electronic devices, industrial devices, medical
and healthcare devices to information and telecommunication devices; besides, it
supports a lot of manufacturing and industrial sectors. It has the responsibility to
create all technically sophisticated digital devices for the future.
Electronic device capability together with material is expanding in vehicle
infomercial and safety systems, manufacturing facility robotics and automation
for industrial applications. Increasing technological innovation, consumer demand
for smaller, much more effective tools with a never-ending amount of functional-
ity over and above the fast proliferation of mobile devices are driving the develop-
ment of electronic devices, market in a cost-effective manner. Significant changes
can be seen in electronic product manufacturing that consists of a greater level
of product combination, integrity, far better performance, increased number of
products produced and minimized costs of device manufacturing. Original equip-
ment manufacturers (OEMs) and original design manufacturers (ODMs) are
significantly transforming product development process and new product develop-
ment (NPD)/new product introduction (NPI) to electronic manufacturing service
(EMS) providers.
Semiconductor manufacturers, from EMS providers to ODMs to OEMs and small
to medium contract manufacturers, are frequently under pressure to introduce mod-
ern technology modifications to provide top-quality products. Manufacturers from
the electronics industry deal with large challenges in regard to international competi-
tion with other suppliers. Extreme time pressure and diminishing shipment durations
while being able to maintain constant quality at the same time suggest that optimal
preparation of sources is necessary. Success in the hi-tech market typically depends
on an organization’s ability to supply innovative, affordable products to the market-
place, before the competition does. Digital suppliers have already dealt with this
principle to change assembly line into completely automated connected factories.
Industry 4.0 not only drives new modern technologies and smart products, but also
additionally serves to broaden the manufacturing.
DOI: 10.1201/9781003190677-5 67
68 Industry 5.0
TRAIL TOWARD DIGITAL ECOSYSTEM

While steel was the main component of the initial industrial transformation, semi-
conductors play a vital role until today and beyond in most of the industrial sectors. It
is thought to be a crucial part of the next generation of electronic innovations; finding
moral paths to sourcing products will certainly assist to drive the advancement of
industrial digital transformation. Global consumers require more configure-to-order,
make-to-order and assemble-to-order products. Mediocre processes and poorly inte-
grated systems mean doom for EMS, particularly in today’s age of rapidly altering
consumer needs as well as modern technologies. Semiconductor manufacturers man-
age complex concepts to transform their own production lines right into completely
automated smart connected factories. For the semiconductor market, the high cost
of wafers makes attaching electronic components to the front opening universal pod
totally practical and provides huge benefits to boost production performance.
The need for inexpensive, low-mix high-volume, high-mix low-volume adapt-
able semiconductor manufacturing EMS providers and OEMs requires leading-edge
automation with control options that help consumers satisfy their business and tech-
nological objectives. Manufacturing of integrated circuits is very complicated and
comprises numerous process steps, each influencing change to the silicon wafers at a
microscopic degree. Semiconductor manufacturers consist of a variety of categories
ranging from customer electronics to industrial to automobile. Traditional semicon-
ductor production counts on a deal with the process recipe integrated with a timeless
statistical process control (SPC) that is used to monitor the production procedure.
Groundbreaking manufacturing procedures call for higher degrees of precision and
accuracy, which require using tighter process control. Yield is attained by advance
process control (APC). APC becomes an important element to boost efficiency, yield,
throughput and versatility of the manufacturing procedure making use of run-to-run,
wafer-to-wafer, within wafer and dynamic process control. Consumer short delivery
and lead time demands are leading inspirations for adopting automation in manufac-
turing electronic facilities.
Automation in addition to integration is the secret to success in contemporary
semiconductor manufacturing. Fabrication of semiconductor items demands inno-
vative control on top quality, irregularity, return and dependability. It is vital to
automate most of the semiconductor production procedures to ensure the correct-
ness, efficiency of process series besides the equivalent specification settings, and
to integrate all the fab tasks to provide effectiveness and integrity, together with the
manufacturing schedule. Automation will give intelligence and control to drive the
procedures of semiconductor manufacture, in which layers of products are deposited
on substrates, doped with pollutants and formed using photolithography to create
integrated circuits.
Electronic device production is increasingly affordable as significant investments
in capital tools are called for to fulfill consumer demand for greater performing tools
with higher functionality. Adding acumen to raw materials of electronic components
promotes the totally decentralized operation designs connected with Industry 4.0.
The advancement of standard electronics production is influenced by the gradual
expansion of the global electronic devices market to emerging markets, along with
Transformation in Electronics Industries 69
the constant rise of process and labor costs related to electronics item manufacturing.
Variables augmenting the growth of the automation market include the need for func-
tional effectiveness, innovation, system assimilation and development in machine-
to-machine (M2M) communication innovation. Electronic device manufacturers not
only transform their very own facilities into smart factories to expand from design to
manufacturing, but also develop new business versions as they launch their unique
digital transformation.
PROCESS AUTOMATION REVOLUTIONS

Electronics component manufacturing and assembly is just one of the most intri-
cate production environments in the industrial sectors globally. Most of the opera-
tions such as the fabrication procedures, assessment and product handling were done
manually. As the dimensions of the elements reduced, device resistance to particle
and other sorts of contamination became even more reduced, such that there is essen-
tially no resistance to contamination on wafers, masks and others. Process modern
technology has evolved to the point where low to zero levels of contamination have
become the standard within the procedure and equipment settings throughout the
EMS providers and OEMs.
Printed circuit boards (PCBs) are the core of any electronic- and microprocess-
regulated powered gadgets over and above the most important required element of
the electronic device industries. It creates the base for supporting wiring and surface
mount of tiny components in electronics. PCB inhabited with digital components is
called a printed circuit assembly (PCA) and the procedure of the assembly is called
as printed circuit board assembly (PCBA). PCBA process is an extremely specialized
and precision-based procedure to be carried out within the venture. The process has
different phases including soldering paste to the board, picking and placing the parts,
soldering, inspecting and screening. All these processes are called for and need to be
monitores to ensure that the finest quality of the product is generated.
Electronic Design Automation

The electronic industrial sector functions closely with the vertical sectors of mod-
ern technology such as automotive, aerospace, medical and other industrial markets
that have detailed requirements. Digitalization of the hi-tech industrial sector has
actually created a brand-new and expanding market for electronic design automa-
tion (EDA) for designers. Electronic component developers as well as service techni-
cians were using a photoplotter to provide drawings of the circuit board, electronic
components, and so on, which over time had actually been replaced by EDA. The
flourishing automotive industry, Industrial Internet of Things (IIoT), artificial intelli-
gence (AI) fields drive the development of the semiconductor market, which requires
digital tools with complex design layouts. Automation makes provision for end users
to enhance, customize and drive the capacities of digital design, test and verifica-
tion using a scripting language and associated support energies. EDA helps in the
specification, design, confirmation, application and examination of electronic sys-
tems. Such that, these can be produced either as an integrated circuit or multiple of
70 Industry 5.0
them mounted on a PCB. In the automobile market, OEMs are buying EDA software
application to establish the next generation of electrified, autonomous cars; in a simi-
lar way, in aerospace sectors, EDA capabilities are becoming more and more vital as
avionic systems expand in intricacy.
EDA presence in design is the expanding need from auto industry establishing a func-
tion called Advanced Driver Assistance System (ADAS). ADAS is driven by the devel-
opment of AI, ML and Deep Learning (DL) advancements.
(Ansys, n.d.)
Increases in the intricacy and electronic device content in the automotive and aviation
industry are requiring changes in the computer-aided design/drafting (CAD) tools uti-
lized to create electric distribution systems and wiring harnesses. Advanced silicon
chips power the outstanding software application that has been used in day-to-day
tasks in the business. They are the structure for every little thing from mobile phones
and wearables to self-driving automobiles. Among the tough areas for the EDA market
is radio-frequency (RF) design innovation. The RF integrated circuit (RFIC) designer
wants to reduce prices; the goal is to obtain as many easy components onto the chip as
feasible. Patterns developing in the electromechanical design of wiring harness systems
include wire synthesis, auto-transmitting and automated generation of wire diagrams.
Failure Process Analysis

Challenges occur each day in digital design and manufacturing. Automation is the
future of quality control. One crucial question that emerges is, as “Just how to review
and maximize PCB design and manufacturing process.” The simple answer is it can
be accomplished by design failure mode and effect analysis (DFMEA) and process
failure mode effects analysis (PFMEA). DFMEA is an approach for analyzing poten-
tial issues early in the product design and development cycle, where it is simpler to
take action to get over potential problems, thus enhancing integrity with product
design and substantially improving safety and security, quality, distribution besides
expense. Fringe benefits from the DFMEA can be acquired through reason chain
evaluation and mistake-proofing (i.e., poke yoke) to decrease risk priority numbers
(RPNs). PFMEA helps manufacturing enterprises to build process safeguards to
counter potential failures from occurring, i.e., determining the resources of failing
and its influence on dependent variables via the manufacturing process. The RPNs
prioritize the failure settings so that restorative activities are required to decrease the
frequency and severity and enhance the detectability of the failure mode. Most of
the manufacturers have actually been changing toward remote work, and the indus-
trial economic situation in the years 2020 and 2021 is facing the appearance of new
health risks due to the COVID-19 pandemic, which has forced organizations to rap-
idly adapt touchless manufacturing processes to satisfy compliance obligations to
keep the labor force healthy and balanced. Therefore, quality management system or
quality lifecycle management system enterprises can restrict the quantity of time as
well as the sources they are taking into managing quality control.
Another important factor to consider while designing PCB by the EMS provid-
ers and ODMs is the decrease in product design cycle and the production expense,
thereby enhancing yield. An important element of the product concept and design
process is that an electronics-based item that can be effectively and cost-effectively
generated is a design for excellence (DFx). It is an essential part of the NPD/NPI
process. It helps in capturing everything before production and comes to be the liai-
son between the consumer and the product design team. Having DFx at a very early
stage of design process, unneeded design and production holdups as a result of PCB
manufacturer mistakes, tests access concerns, as well as out of date products, are got
rid of, which ought to be the biggest value added for the EMS providers and ODMs,
even for the small to medium contract suppliers. DFx targets the product value deliv-
ered to the customer, and it includes design for supply chain (DFSC), design for
reliability (DFR), design for fabrication (DFF), design for assembly (DFA), design
for manufacturability (DFM) and design for test (DFT). After the product design is
done, the manner in which the PCB manufacturers perfectly incorporate the whole
PCB production process and the use of PCB DFM evaluation helps to review and
simplify the product design factors to be considered.
A glimpse on how PCB manufacturers can utilize automatic DFx tools to use their
interior design rule checks (DRC) to supply comprehensive DFM records for design
testimonials follows. DFSC is done early in the design cycle, which helps to deter-
mine the picked supplier component numbers’ lifecycle state, accessibility, procedure
compatibility and legitimacy that addressed prior to preliminary design. DFF assists
to evaluate consumer designs as early as feasible, where it is very easy to make deci-
sions that clear out price, improve manufacture returns and address issues before the
final design is completed. DFA together with DFR reports plays a vital role to provide
understanding right into product failures. Using Six Sigma, the estimated annualized
price avoidances can be assigned to prioritize design modification decisions, and the
evaluation can be executed to deal with issues early in the product design addressing
prospective reliability problems. DFM integrates supplier detail equipment demands;
particularly, manufacturing procedure demands are related to establish the process
and eventually the control strategy to effectively deal with the DFMEA and PFMEA.
PLM assists to deal with leading DFR obstacles by automating processes, boosting expo-
sure, access to vital information, and also engaging DFR early in the NPD/NPI process.
(Paganina and Borsatoa, 2017)
High quality product and product reliability is one of the most vital areas in the
PCB manufacturing sector. It is vital to guarantee the quality of products, since the
decision-makers throughout the product advancement decide on the high quality and
price of the product. The details collected about design and process failures vid-
eotaped with DFMEA and PFMEA provide a really important understanding for
future product and process design. Effective reliability engineering has the capacity
to predict those parts of a product that may stop working along with the performance,
safety, security, and financial effects of failing. Successful DFR is supported by
effective product management methods. In the age of Industry 4.0, the arrival of IIoT
along with product lifecycle management (PLM) systems produces a closed-loop,
data-driven DFR program to improve predictability and integrity and attain better-
performing products. PCB small to medium contract manufacturers, ODMs and
EMS providers need to check out leveraging their product design and development
72 Industry 5.0
making use of PLM, the system utilized to create their product, as a resource to
connect other systems and data right into DFR to create an all-natural sight of the
product development processes.
Transformation in PCBA Process

Currently, the increasingly affordable electronic device sector, product demand drive
increase the supply and and conversely boosts the rate, so the capability to inte-
grate continually high criteria of quality and precision with optimized productivity,
reduced manufacturing expenses and fast process times is important. The goal is to
inevitably improve client worth as well as to preserve shareholder rate of interests
with enhanced margins and better visibility on the market. Innovation has actually
considerably enhanced the electronics manufacturing market. While incorporation
and automation are transforming the means the electronics sector works, the indus-
try has been slow-moving to catch up. EMS providers, ODMs and OEMs consider-
ably gain from automation, which creates faster manufacturing, less mistakes and
limited demands on humans. Limited tolerances and delicate nature of electronics
made robot automation challenging, but development in robotic innovation enables
manufacturers to understand the benefits of robotic automation and is among the
largest segments of the robotics industry worldwide. Robots help in managing even
the minute details with accuracy accuracy and substantially increasing throughput
to reduce unit prices. The fast adoption of robotics helps in quick completion and
enables EMS to be extra productive as compared to the competitors.
Manufacturing of smart digital products, making use of microelectronics to shift from
manual to semi-automated procedures fueled the adjustment from THT and also wave
soldering modern technology to SMT.
(Whitmore and Ashmore, 2010)
By removing delays, avoiding accidents and mistakes, improving management,

as well as producing brand-new business paradigms, automation has significantly
transformed electronics manufacturing industrial sectors. Through-hole technology
(THT) assembly is used at first by hand soldering a wave solder equipment, wherein
openings are drilled right into the PCB for installing of the components, besides sol-
der is wicked up right into the holes to finish the circuit’s connections. Advancement
of automation in the electronics industries made manufacturing enterprises to begin
utilizing surface mount technology (SMT), where digital components are put together
with automatic equipment that places elements on the surface of a PCB. As opposed
to traditional THT procedures, SMT elements are positioned directly on the surface
of a PCB rather than being soldered to a cable lead. When it comes to PCBA, SMT
is one of the most regularly used processes.
PLM for PCB Design

Products are updated to new variations and capacities, and new components are
included, lapsed and changed with totally new circuit layouts and innovation.
Industrial markets across various domains acknowledge the vital duty that electronic
devices play in the distribution of ingenious products, so effective management of the

entire electronic component life cycle in the context of the end product is important.
Managing product design, development, manufacturing and distribution are just one
facet of taking a new item to market. PLM allows PCB designers to quickly take
advantage of PCB data management performance while operating in the native elec-
tronic computer-aided design (ECAD) setting. PLM assists to find the ideal electronic
device information promptly by making use of abundant data administration capaci-
ties and get rid of irregular and imprecise PCB component information by making
use of enterprise-wide ECAD components’ library administration. The practice of
reusing parts has significant implications beyond merely reducing expenses related to
design through the manufacturing job by recycling parts in NPD/NPI. PLM helps in
automating and systematizing engineering procedures by integrating items and pro-
ducing details, illustrations, thermal evaluation and simulation in the bill of material
(BOM). Bi-directional data exchange in between PLM and PCB makes it possible for
NPD/NPI teams to quickly connect with PLM in the context of their design layout
environment, significantly boosting the capacity for engineering to leverage the PLM
system to help drive product development ahead.
Business Challenge
Electronic engineers of small and medium contract suppliers and EMS needs to have
accessibility to critical data such as life cycle, stock and rates during the initial design
phase so they can make decisions in advance. Digital and electrical design layouts are
based on detailed descriptions of several elements such as electric residential proper-
ties; supply status and information are generally held individually in CAD libraries,
enterprise resource planning (ERP), manufacturing execution system (MES) and so
on; however, there is a significant danger that design, sourcing, manufacturing speci-
fications may get out of sync.
Precondition
The ECAD application is used for modeling PCB, supplier components and details
about the customer’s name, part number, sourcing information and ECAD library.
Approach
Product data management helps NPD/NPI teams along with PLM to successfully
deliver tasks consisting of BOM monitoring that includes schematics and drawings,
document monitoring creation and updating supplier data, configurable workflows
and ability to track the job of the product advancement. With the technical innova-
tion of smart connected products, PLM integrates with ECAD and mechanical com-
puter aided design (MCAD) combines electronic devices data and design processes
with mechanical data, so cross-functional teams (CFTs) can interact across design
techniques and diverse enterprise applications. PCB design integration is the basis of
electric design data management. By integrating ECAD with PLM system, product
managers anticipate to minimize time to market, protect against mistakes and data
storage problems and produce an extra skillful design review workflow resulting in
better products. Having access to ECAD library helps to decrease product prices and
help to conform to environmental regulations. CFTs share evaluation data in a digital
74 Industry 5.0
environment throughout the extended group, therefore decreasing the need for physi-
cal models, shorten the development cycle and lower product development prices. A
more vital process to consider is incorporating EDA with PLM, which helps in the
reduction of product advancement time.
Result
The PLM provides security for the IP data while increasing design and development
effectively by making it possible for PCB design teams to capture, handle, locate and
reuse the ideal information from a solitary secure place. Tracks and takes care of
product environmental conformity information within a single safe area consisting of
IPC-1752 product material declaration throughout the product life cycle. Access to a
full series of PLM capability makes it possible for the NPD/NPI group to take care of
archived PCB data effectively and to optimize design through production processes.
The electronics NPD/NPI team can maximize sources, reduce mistakes and project
holdups and minimize total design costs. Regulated accessibility to all electronic
device design information any time makes it possible for collective, multidomain
codesign with complete traceability throughout the advanced product life cycle.
Quality Assurance
The NPD of a digital product consideration is given to the functional life cycle, during
which the product needs to function without fail, commonly in the form of a service
warranty. Quality assurance is essential for all PCB as well as electronic device manu-
facturing. PCB manufacturing is in the eye of a speedy advancement today, much of
it performed in service of miniaturization. Precise information that is legible besides
being accurate is essential for board fabrication and assembly devices in PCBA man-
ufacturing procedures, which can be helpful for traceability throughout the whole
product development life cycle. PCB manufacturing is based upon the performance
category as stipulated in IPC-6011 and IPC-A600 generic efficiency requirements for
PCB. The use of digital twins and virtual testing permits product designers to obtain a
complete picture of how the PCB, its parts and the end product are integrated and will
operate in the real world. The quality lifecycle management helps EMS providers and
ODMs to unify all top-quality-related activities across the supply chain for a natural
understanding of product high quality and reliability. Quality management system
(QMS) supplies automatic DFMEA and PFMEA and enables closed-loop corrective
action and preventive action (CAPA) along with root-cause analysis (RCA) to accel-
erate recognition, control and analysis of concerns along with tracking of affected
products. The QMS is needed to achieve conformity with regulative needs and high-
quality standards. It integrates with PLM to become an eco-platform to retrieve and
receive details and help identify problems early in the design process.
Industrial Robots
Robotics automation has terrific potential in PCB and electronics components
making and applies to almost any type of phase of the entire manufacturing life
cycle. PCBA requires extremely rapid, precise placement of small objects that are
Defect Mapping PCB test

PCB Test Station PCB Board Tool User Interface
Engineer
• Auto Track Defects

• Auto Mapping • Screen gets refreshed • Perform process
Test run to gets started yield
discover any Feed the board once the system
details via MES • Place of detects new defect improvement
defect Discover • Root cause
• Reports generated by
mapped to Place the station and by the analysis
of Origin component
FIGURE 5.1 Automation defect mapping process in test station
often fragile. Industrial robots have the ability to carry out numerous jobs in turn,
e.g., installing different kinds of elements on a base plate. It can manage display
screens put together ports; build subassemblies; and apply adhesives, assessments,
screening, packaging and more. Developments in grippers and vision technologies
along with pressure sensors imply robots have to deal with a significantly large range
of production, setting up and completing tasks. Force picking up allows for compo-
nents to be finessed right into the location. When combined with flexible component
feeders and vision systems, robots add flexibility to PCBA. Robotics assists PCB
manufacturers with the adaptability to switch swiftly in between product variations.
For small and medium contract manufacturers, any type of gain in efficiency will
certainly have a significant influence. As the cost of resources for chips, fiber cables,
circuits and various other essential electronic device parts drops, manufacturers have
actually turned to industrial robots to enhance operational efficiency and effectiveness
and minimize labor costs without harming the quality and precision of finished equip-
ment. Robotic assembly can adapt to the tolerance disparities, conveniently locating
as well as adjusting the pieces as needed. With the decline in the setting up time,
industrial robots are enhancing productivity in lots of electronics production facilities.
Likewise, they assist in conserving cash on labor and manufacturing costs, as they
pass those financial savings along to their customers. In PCB’s too, there are new tech-
nologies happening in the robot sectors, in terms of size and much less programming.
Tiny robots are utilized to construct automobile electronic control units, smartphone,
PCBs, and so on, and to assist in testing and in the examination of tiny components.
Small to medium enterprise (SME) contract manufacturers are progressively looking
to robots as a result of their ease of use and versatility, and their joint capability posi-
tions them well for automation. It is essential to understand that robots are not meant to
replace workers but to make work easier for skilled specialists. As the industrial eco-
nomic situation prefers a hybrid approach, safety and security is of primary concern.
PROCESS TRANSFORMATION REVOLUTIONS

Modern industrial innovation is helping various companies in various industries
progress at a much faster rate. Hi-tech electronic device systems are the foundation
for turbulent changes occurring in industries ranging from mobility to automotive to
energy, to the fourth industrial change. Electronic industrial transformation has struck
the telecommunication industry; the competitors in the field have made huge financial
76 Industry 5.0
investments and advancement, leading to boom the industrial digital economy.

Speed is crucial in today’s service globally and thanks to modern technology, man-
ufacturing enterprises have currently accelerated their service speed. 5G, autono-
mous vehicles, smart products, smart houses, smart cities and smart factories are in
vogue, making it possible for electronics and modern technologies need to deliver
unmatched degrees of reliability.
Ingenious electronic manufacturing is a main lineament of Industry 4.0, and
also, manufacturing enterprises require to compete with one another by lowering
expenses and enhancing performance by using innovation. The fact is that hi-tech
electronics manufacturing welcomes a wider variety of activities beyond manufac-
turing; consequently, strengthening electronic production industries is important for
sustaining international competition. The modern technical trend is moving toward
smart and incredibly effective products, preferably with integrated safety features in
addition to energy harvesting abilities. Complex products are manufactured based
on customer demands by small to medium contract manufacturers, EMS providers,
ODMs and PCBA businesses that have actually adjusted their operations to brand-
new techniques of functioning. Similarly, integrated factories efficient in automa-
tion of complex as well as cost-effective products should make right investments
in manufacturing facilities, transforming them into smart connected manufacturing
facilities.
As technical innovations become quicker, transformations will inevitably follow
one another in fast sequence in the coming years and beyond. The very first three
industrial transformations took decades to play out whereas today’s transforma-
tions last only as long as it considers industry-wide application to complete itself.
Industry 5.0 integrates human employees, AI and manufacturing facility robots as
they collaborate on designs and share work across PCBA manufacturing proce-
dures. Developments in various innovations help EMS providers, ODMs and small
to medium suppliers to move forward and embrace industrial transformation.
Simulation
Electronics and high-tech industries innovate at lightning speed to survive. Smart
products have complex electronic systems that call for smooth real-world operations.
Product developers encounter a challenge, as electronic devices are responsible for
large scale thermal emissions; when a signal is sent out down a cable, it reverberates
and discharges electromagnetic fields that interfere with various other parts of the
product. Suppliers face a high level of variation because of, continuously shrinking
batch dimensions and fluctuations in order to quantity that are increasingly difficult
to forecast. With innumerable sensors, microprocessors and communication parts,
product designers deal with tremendous product integrity and performance chal-
lenges with the miniaturization of gadgets, the support for multiple cordless technol-
ogies, faster information prices and longer battery life need to go through extensive
need analysis. Simulation-led electronic improvement enables businesses to launch
new products more quickly, at a lower cost with fewer resources. Engineering simula-
tion plays an essential role in assisting the manufacture of cutting-edge and reliable
products that accomplish and surpass target effectivity, energy efficiency, price and
speed-to-market objectives.
Few simulations carried out are static, and dynamic stress evaluations can be
executed for mechanical parts and casing structures. Liquid flow together with
multicomponent thermal evaluations prevails simulation techniques for electron-
ics parts such as chips, diodes, resistors and PCB, regulating the thermal emis-
sions of various products, cooling effects and ecological impacts. Simulation in
PCBA allows to determine production bottlenecks, highlights opportunities to
raise throughput and determine financial saving opportunities such as optimiza-
tion of straight and indirect labor. With the simulation of product performance in
the initial design stage, NPD/NPI CFT groups will have the option to rapidly take
in new modern technologies, with improved design and also much better materi-
als, reducing the operation procedures and testing. It is necessary that all divisions
involved in the electronic device manufacturing process should connect and also
collaborate based on the exact same digital version.
Few questions to be answered by EMS, ODMs, small to medium contract manufac-
turers before choosing appropriate simulation tool depending on the PCB functional
requirement such as input signal, conversion of data from analog to digital, domain-
based time and frequency sweeps.
(Peterson, 2020)
Simulation technologies have improved and are integrated as part of the schematic
capture program. It gives the PCB designer opportunities to check and also replicate
the circuit essentially before proceeding to the PCB format and enables the NPD
team to evaluate different materials for the elements and optimize layouts. Unlike
traditional model testing, simulation enables engineers to practically examine just
how a given product design will work well before any type of physical model is
constructed against a wide variety of scenarios, some of which might be impos-
sible to duplicate experimentally. Simulation spans the product design continuum to
fuel open interaction between diverse design teams from electrical, mechatronics,
mechanical to thermal and fluid dynamics. Simulation cannot build PCB; however,
the outcomes will supply some useful insights into design modifications that can
boost performance and fulfill customer requirements.
Augment Reality
Advancements in device equipment to smartphones are taking over the world like
a tornado, and the hi-tech electronic industry has frequently proved itself to be at
the lead of technology adoption. The development of advanced technologies such as
AR and VR in the electronic industry is a significant revolution. These technologies
simplify work for PCB designers in bringing the products to digital life, and they
also make it quicker and safer for the manufacturing groups to assemble the elements
of the PCB. Both the technologies are transforming businesses across industries
and customer electronic device sectors, and the outcomes are effective. AR and VR
address concerns such as fitting electronic packages into unusual forms and ensure
circuit connections are working correctly while reducing the taxing procedure of the
area and path in PCB production. In a nutshell, AR and VR provide PCB design-
ers and manufacturers a true feeling of range and also closeness to have a far better
understanding of the design early in the product life cycle.
78 Industry 5.0
PCB Test Station PCB Test Station
PCB Board is Fed Scan PCB Board using

AR assistance
Upgradation
Static Auto mapping Dynamic Defect

mapping
Defect detected Defect identified with

Process Process CAPA
Automation Transformation
Root Cause Analysis and Results are automatically

Manual updating updated and verified by
Human Intelligence
FIGURE 5.2 Defect mapping transformation using AR.
Additive Manufacturing
Additive manufacturing (AM) or 3D printing and electronic devices are highly
connected. Personalization has become a huge asset while making use of AM for the
creation of PCB and various other electronics items. PCBs are little; the procedure to
model and manufacture them is rather prolonged. The arrival of 3D printing has actu-
ally introduced a new age for PCB development; it can create parts flawlessly adapted
to a PCB for any type of electronic devices. It also clarifies complicated geometries
that are difficult to make with various other conventional manufacturing techniques;
moreover, it does not need any type of assembly procedure and also helps in reducing
procurement expenses while removing any concerns about IP violation. A complex
PCB can be created at a reasonably low cost, with the rapid turnaround allowed by
AM; today, PCB board is quickly offered. It allows electronics component engineers
to develop for functionality rather than manufacturability; those complex frameworks
with ingrained electronics, enveloped sensors and antennas are readily manufactured.
Material choice is one of the essential factors to consider for an engineer when it
comes to picking a PCB manufacturing method. Electrostatic discharge (ESD) is a
real problem and a huge issue for the electronic industries, and having the ability to
make ESD risk-free component is a real benefit to prevent any issue. ESD materials
exhibit low electric resistance while using the required mechanical-, thermal- as
well as chemical-resistant residential properties. ESD-safe 3D printing is used in
jigs, fixtures and housings for electronic device making. AM is transforming every
one of the methods by enabling suppliers to design and print jigs, fixtures and com-
ponents with sophisticated engineering-grade materials that fulfill ESD surface
area resistance demands.
AM printer from few manufacturers makes use of product jetting technology to pub-
lish multilayer PCBs with numerous features including interconnectors. Few busi-
ness applications comprise of sensing unit modern technologies, radio frequency area
systems and also IoT communication gadgets. Space sector has actually been a hefty
adopter of the Polyetherketoneketone (PEKK) based ESD material in order to meet
their chemical, warmth, and electrostatic discharge requirements for space trip.
(AFMG, 2019; Roboze, n.d.)
AM is positioned to play an integral part in production lines; extensive fostering has

actually been obstructed by limited access to a wide collection of products that meet
requirements for dependability, repeatability effectivity of 3D-published parts in the
industrial ecosystem. 3D printing only utilizes products that are vital to construct the
end item; much less material is used, which reduces the manufacturing costs, gets rid
of waste and also minimizes the manufacturing time from a number of weeks to a
couple of hours. 3D printing in the electronics industrial sector decreases warehous-
ing and distribution expenses thanks to on-demand production and the possibility to
create a digital stock. AM will certainly be a practical method for generating wear-
able, embedded sensors used in mobile phones and real-time health tracking. As the
modern technology grows, expectations arise that 3D printing of electronics could
ultimately shift from being only a prototyping device to direct end production.
Smart products made using materials such as composites, functionally rated mate-
rials, form memory materials, multiphase products, and biomaterials play a critical
role in applications such as conductors, actuators, sensing units, soft robotics and
wearable electronic devices. 4D printing innovation is in the pipeline, which will
certainly facilitate the growth of electronic device manufacturing on plastic foils uti-
lizing natural thin-film transistors, whereas boosted conducting polymers are being
established for organic electronic devices.
Robotic Process Automation

Digital labor force is the backbone of most of the repeated processes these days. These
digital employees include automated software bots, which are helpful for the back-
office operations. Human reliance on Industry 4.0-based technologies brought to life
the software application robots namely RPA. The most immediate effect of RPA is
that regular jobs are carried out in an error-free, consistent fashion. There are a couple
of areas where RPA assists PCB manufacturers It can be programmed to examine for
broken traces over pierced and under drilled holes, misplaced parts and so on.
Among the key area in electronics industry is taking care of suppliers, where RPA
review the invoices, extract data, using OCR, update supply details in enterprise sys-
tems (MRP) immediately, besides send notices to numerous needs for production plan-
ners to upgrade supply levels as needed.
(UI Path, n.d.)
The initial step toward implementing RPA is to identify extremely recurring tasks
that are mostly prone to mistakes as well as think about piloting there. It plays a sig-
nificantly essential function in small to medium contract manufacturers, ODMs and
80 Industry 5.0
EMS providers to transform into Industry 4.0. In this smart connected competitive
world and difficult business landscape of high-volume, multistep processes with dif-
ferent authorization concepts and manual processes are automated from end-to-end
with the help of RPA. Based on the business processes that need to be automated and
their outcomes, enterprises need to select the process, followed by the readily avail-
able RPA tool in the marketplace, create, personalize and start implementing the
option for automating the business jobs. RPA software program does not replace the
already existing systems of the organization. In fact, they work in comprehensibility
with the system. RPA is coordinated with any type of software application utilized
by people, and also, it quite possibly may be carried out in a quick amount of time
to accomplish functional strategies. Taking the following action toward Industry 5.0,
electronics manufacturing enterprises need to take on a long-lasting process automa-
tion technique that aims to implement intelligent automation solutions that incorpo-
rate both RPA and AI capabilities.
Process Standardization of SMT

The business challenge is to obtain PCBA manufacturing functions to get in touch with
the real-time information system making it possible for the anticipating technique in all
features to provide greater stability and high-mix low-volume production environment.
Process standardization of SMT line results in
• Conveniently locate as well as keep an eye on key supply raw materials,

final products, components and also containers to maximize logistics, pre-
serve inventory degrees, stop quality issues and spot theft.
• Connect manufacturing facility assets and PLM, ERP, MRP, MES, DMT
and MSD systems to provide role-based views using augmented reality
experiences.
Solder Paste Component Automated Optical Reflow Solder Joint Circuit Command Center Room
Printer Cleaning
Inspection Placement Inspection Oven Inspection Testing
Printer Parameters SMT Attrition AOI • SPI Variables SPC

• Speed • Line Attrition • FPY • Reflow Variables M2M and
MES • Pressure • Table Attrition • Top Failures • Solder wave Realtime
Enterprise Applications
• Temperature • Component • Result by SN Variables Data Dynamic DB

Attrition Collection
DCS RTU
Industrial
Control
ERP, MRP System SPC, AI-assisted
PAC PLC Cobot SCADA / HMI Predictive Reports and
Human-assisted CAPA
IIoT
Dashboard
ECAD, PDM, Enterprise
PLM Board , MSD PAD ID and Machine
Line Issue First Pass Yield
and DMT Parameters
FIGURE 5.3 Process standardization of SMT line using IIoT.

• Enable real-time surveillance and predictive diagnostics of possessions to

automatically trigger and proactively launch upkeep teams to reduce down-
time and to identify maintenance and quality issues before they occur.
• Incorporate, assess and deliver insights from disparate and diverse silos
of assets, drivers and also business systems right into unified real-time
visibility of KPIs for enhanced operational effectivity and improved
decision-making.
Cobots
Cobots give electronics manufacturing enterprises the agility to automate nearly all
the hand-operated tasks while adding worth to the businesses. Cobots make automa-
tion affordable and are a practical solution particularly for SME, EMS providers
and ODMs as cobots are helping them compete better. Enabled by ML and geared
up with innovative sensing modern technology, cobots work securely together with
human beings, tackling dangerous, recurring and also significantly complex tasks.
Cobots are redeployed over and over again in different duties to satisfy consumers
raising the need for brand-new products, making them a valuable long-lasting invest-
ment and also a crucial innovation of the electronics industry. Semiconductor mod-
ern technology is making it possible for advancements in motor control, sensing and
commercial interactions that allow cobots to function efficiently and securely on the
factory floor. It coordinates with employees to highlight their finest and to transform
the technological development in addition to a hike in top quality and productivity.
Integrated sensors are completely suited for the delicate job of dealing with electronic
components, securing delicate components and pricey fixtures, makes cobot a cost-
effective, high performance automation device for PCB handling and in-circuit testing.
(Universal Robots, n.d.)
The ML abilities make cobots to train various other cobots by sharing the details they
discovered in-house as well as remotely from the cloud. With innovation transform-
ing daily and manufacturing processes evolving perpetually, OEMs and EMS provid-
ers continuously have to adapt to the technical advancement of Industry 4.0 through
Industry 5.0 to make manufacturing smarter, faster and more cost-effective products.
Ideal security criteria are particularly crucial while implementing cobots; it comprises
sensing units that allow it to be familiar with its surroundings, for fast, exact and safe
operation. Data from these numerous sensors are refined rapidly, so the cobot reacts
accordingly. With the arrival of AI, the cobot responds ever more suitably to the infor-
mation accumulated from sensing units. This indicates that cobot can examine infor-
mation, factor, resolve challenges and find out just how to respond to new scenarios,
making decisions individually and interacting with the shop floor personnel.
Most of the electronic component suppliers are passionate about embracing the
innovation since they will certainly operate in association with the workers in con-
strained rooms, production line without requiring any fencing and therefore con-
serving costs on the area. Cobots are an inexpensive modern technology with a
much faster return of financial investment in the initial years of implementation.
Small to medium contract suppliers, EMS providers and ODMs make the most of
82 Industry 5.0
the possibility of using cobots with complicated applications in automation that

increases the production quality while raising productivity with very little additional
cost and also manpower requirements. Another essential element is designing cobots
the electronic noise that interferes with electromagnetic fields, security and also
ergonomics are some design challenges to be considered. The interesting thing is
that as innovative technologies establish further, cobots will become ever better and
more prevalent in the future industrial economy.
Artificial Intelligence
The artificial intelligence (AI) growth in the electronics industrial sector is fairly
apparent. Powered by innovation as well as a flair for adjusting swiftly to arising trends,
the electronics manufacturers have gone mainstream and fundamentally altered the
method electronics components and end products are designed and developed. One
of the most anticipated AI applications is using its potential in making the enterprise
more anticipating and also flexible to a changing business atmosphere; this will assist
electronic suppliers in creating a solid foundation for building cutting-edge electronic
smart devices for the future. AI concentrates on bringing about significant modifica-
tions not just in the financial aspect but also in safety and actual operation control.
It has become critical to include AI to get ahead of the global competitive market.
The need to enhance client experience is high, and consumers are choosing tools that
could provide even more personalized experience in terms of interaction and comfort.
The electronics industrial sector flourishes because of three significant advancement
that comprises innovative analytics with insights, autonomous business procedures and
AI-powered immersive experience that achieves more participation from the customer.
AI computational power and advanced analytics at lower expenses can help small to
medium contract manufacturers examine numerous information factors and historic
information to expect machinery failure enables upkeep before it takes place. AI uses
information to gather understandings besides spot patterns to determine sources of low
yields and areas that require attention. Based upon the details, executing prompt and
optimal modifications to production processes can enhance yields.
BUSINESS CHALLENGES OF PROCESS TRANSFORMATION

Technological innovation path is shifting toward smart and very efficient products
that are with incorporated safety, security and protection features besides effective
power harvesting capacities. Process transformation of EMSs and PCBA enterprises
is vital to sustain competition and enhance manufacturing processes, reducing blun-
ders and managing the manufacturing processes related to production and assembly
of electronic end products. Electronics suppliers are urged to utilize their experience
to establish not only their products, but also their own product design and process
innovations. The link to the network is an important part of the process transforma-
tion. Speeding up the pace at which these procedure improvements are being made
forces EMS providers, ODMs and also OEMS to constantly remain at the center of
innovation in order to continue to be competitive.
Industry 4.0 through Industry 5.0 creates new trials and risks along with brand-new
chances for electronics suppliers, who prepare to accept and invest in digital industrial
economy. It will not only change an enterprise’s own facilities into smart factories
to expand manufacturing of new products but also build new organization designs
as they embark upon their own business process transformation. Among the critical
challenges for electronics firms is that it varies widely depending on the volumes,
mix of items and running models: low volume, high mix; high volume, low mix; and
medium volume, medium mix besides specializations, according to whom they sell to
in industrial sectors such as automobile, energy, aerospace, defense or medical, and
so on. Welcoming process transformation is also about embracing a mindset of fre-
quently learning how to enhance production in addition to supply chain management
and product distribution.
The effectiveness gained by the industrial transformation places electronics manu-
facturers in a possition where they have the ability to be much more active and versatile
to respond to new possibilities. All electronic devices suppliers ought to be leveraging
the data that currently stay across the whole supply to enhance specific processes in a
fashion that contributes to the better the whole, instead of nearly adding innovations to
their organization procedure. The success of smart process transformation is directly
related to the acknowledgment of its added worth. Furthermore, it will be essential
for firms to establish their basic strategic program at an early stage to gather experi-
ence matching innovations. It is expected that complete industrial transformation will
certainly take electronic production services to an additional degree in regard to cost
and quality.
Process transformation is likely to demand new abilities besides training that
area greater focus on the communication between equipment and operators. Smart
devices used in this transformation are successfully used to fix real-time issues. It is
also most likely to ask services to believe in different ways about their use of indus-
trial robots, cobots over and above how they handle their data. It assures boating of
benefits for electronic devices manufacturers. There exist great deals of opportunities
to improve operational effectiveness and boost performance by sharing workloads
throughout electronic manufacturing procedures.
BRIDGING PROCESS AUTOMATION TO

Advanced process control and visualization applications are key parts of the automa-
tion to transformation strategy as well as inevitably have come to be the enabler for
completely automated factories. The capacity for suppliers to track defects all the way
to the PCB devices provides increased process presence through the celebration of dig-
ital data throughout the production line and also the channeling of this data straight to
the manufacturing facility MES with venture applications. Advent of advanced process
control and also visualization marks the very first steps toward a completely automated
factory made it possible for by AI. PCB industry is advancing and also enhancing, not
just in relation to product design through manufacturing and reliability, however, also
in feedback to even more unified sustainable guidelines and commercial standards.
84 Industry 5.0
Sustainable Design through Manufacturing

Effective and reliable electronic component designs are contributing to greener
electronics industrial sectors by decreasing energy intake in exerting to discover new
and also much safer options to materials and processes that present a hazard to the envi-
ronment and people. PCB suppliers are constantly facing difficulties in addressing waste
generation; lowered performance along with increased power consumption always set
back the techniques created to decrease prices. The methods used in electronic manufac-
turing industries are speeding up the transition of making in the direction of a sustain-
able system with production systems transformation and lasting value exchange.
With ecological sustainability being a significant concern today, suppliers are turning
their focus to just how they can use smart innovative technologies to come to be a lot
more active as well responsive in terms of their environmental compliance, plans, and
techniques. One of the methods remains in being effective with resources, lessening
waste, looking at means to catch worth from waste, the greatest resource performance
gains can be made.
(Esfandyari et al., 2015)
Sustainable manufacturing is seen from different dimensions among the industrial

sector which are environment, culture, economic situation, technology and perfor-
mance monitoring. The aim of sustainability is to design and develop manufacturing
process and component, wherein there is absolutely no impact on the atmosphere and
accomplish 100% component recyclability. PCB manufacturers are currently con-
centrating on such merging to realize larger benefits of industrial transformation to
attain sustainable production. Seamless assimilation of cutting-edge technology by
Industry 4.0 that incorporated with Industry 5.0 creates huge amounts of informa-
tion, which plays an essential role in establishing methods from ecological, societal
and financial perspectives. Small and medium-sized contract suppliers mainly con-
centrate on energy effectiveness, performance, competitiveness, expense decrease
and not on lasting manufacturing goals. They require to recognize the benefits of
Industry 3.0 to Industry 4.0 via Industry 5.0 transform themselves right into a smart
connected ecological community lined up with sustainable objectives.
SUMMARY
Developing a digital integration throughout PCB design via production is vital for
generating end products that are premium quality, affordable and on time. Enterprises
require to find out exactly how to make use of automation, AI system, ML, IIoT con-
nectivity, data monitoring technologies to make electronic components more effec-
tively, efficiently and openness. Electronics industry as a whole has been significantly
accepting the IIoT. Spike is popular for electronic device products credited to the
brand-new teleworking regimen throughout the COVID-19 pandemic, which has actu-
ally enabled workers of different industrial sectors to remain to satisfy the demands of
working remotely. When it concerns supply and demand, electronics manufacturers
require reliable and safe systems mostly cloud-based environment to keep operations,
foster interaction within CFT as well as among vendors, representatives and retailers
and take care of the inventories and item directories on an international range.
Based on functional requirements in the production process, the purchase division

makes sure maximum degrees of supply, via the use of ERP systems for making pro-
cess control work monitoring MES for PCBA process within the enterprise. Keeping
huge data source of such elements consisting of non-technical information like mini-
mal order quantity, preparations and pricing. Enterprises of all sizes will certainly
be able to make educated choices based upon the real-time details that these smart
connected tools can provide. Combined with other modern technologies of industrial
transformation can aid drive a lot more effective short-term and long-term decisions.
Effectivity of the supply chain within the PCB manufacturers ends up being
progressively based on vital modern technologies that sustain incorporated plan-
ning, logistics, smart purchase, warehousing and analytics. Sourcing of basic raw
materials, supply components and final distribution of the item to the client, a shift
to an electronic supply chain design uses the capacity for PCB manufacturers to
take even far better control of their supply chain. Predictive upkeep stays clear of
the prices associated with machine downtime, decreased maintenance and repair
expense, which is improved by devices being more resilient. Coupled with data col-
lection, industrial transformation will certainly help in forecast when and just how
a piece of equipment may stop working, permitting enterprise decision makers to
prevent it. As well motivated to use their experience to additionally create not just
their items yet also their own design and process utilizing modern technologies,
as the connection to the network is a fundamental part of the IIoT. Coming on to
the interaction innovations wired or wireless, both will be an increasing number
of sought after in the future and to have consisted of in the profile. Thinking about
ecological destruction, policy waste electrical and electronic equipment (WEEE)
needs to be implemented across the enterprise with the advent of technological
advancement for the disposal of electronic waste in a secure way. Data and IT
safety have an increasingly essential duty for the effective introduction of indus-
trial transformation and need to be executed right into electronic systems as criti-
cal approval and success factors. Industry 4.0 and Industry 5.0 overall are still in
a phase, in which it is essential to realize where and exactly how it can be applied
with existing CFT strengths and innovations properly to fulfill the client demands.
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6 Transformation in
Process and Industrial
Manufacturing Sectors
Industrial manufacturing sector creates a selection of different types of equipment,
from massive industrial to basic household products; some of the industrial products
are product packaging materials, energy-effective unplasticized polyvinyl chloride
(uPVC) products, glass, solar mounting panels, ground assistance devices, commer-
cial valves, oil and gas and pharma products. Industrial manufacturing is a vast field
to know. Efficiency is just one manner in which producing firms can distinguish them-
selves from others, and many ventures in this industrial section are conglomerates
that create products located in numerous sectors. One major fad in this sector is using
increasingly sophisticated manufacturing strategies. Small to medium range enter-
prises following distributed manufacturing development are expected to grow more
as the global logistics market has become more complicated, and the manufacturers
are better connected, as it has become a standard for the end product to be packaged
and constructed close to the end customer. Gradually product transfromation leads in
numerous businesses collecting data and operating in partnership with consumers.
Industrial manufacturing enterprises take advantage of making use of computer
system-created settings that combine real life with digital threads. Current geopo-
litical conflicts and COVID-19 pandemic disturbances have actually reignited the
argument on the future of globalization. In addition to distributed manufacturing
design, warehousing along with logistics requires to be a lot more regionalized sup-
ply chains, including cloud computing and enhanced IT facility solutions to offer the
supply chain the visibility needed to repond to market changes as well as proactively
address the regulatory conformity issues that accompany international development
to make use of expense and operational efficiencies. Industry 4.0 outfits the com-
mercial production industry to strengthen its supply chains, to boost productivity, to
improve procedures and to get a bigger share of the worldwide market.
SOLAR PHOTOVOLTAIC (PV) INDUSTRY

The renewable energy sector is the most needed sector at this time in the industrial
manufacturing sector. Industries throughout the globe are trying to find means to gen-
erate more effectively without causing additional damages to the world environment.
Future manufacturers, either small to medium enterprises (SMEs) or original equipment
manufacturers (OEMs), are being educated on renewable power resources, encompass-
ing the modern technology and the cost facets of renewable resource technologies,
along with their potential which can give important insights. Industrial manufacturers
DOI: 10.1201/9781003190677-6 87
88 Industry 5.0
are huge customers of electrical power and a lot of them come to be a lot more last-
ing; they make great payments to promote a greener and cleaner planet. Knowing the
regulations, certain power requirements, and the increasing relevance of power to drive
the smart factory, there is more attention than ever before for energy effectiveness in
industrial sectors. The fifth in addition to the fourth industrial revolution is about to
bring even more changes in the future industrial economy.
Renewable energies developed an effective brand-new infrastructure for indus-
trial sectors. Industry 3.0 had transformed the world a lot by producing renewable
resource regimen, loaded by structures, partially saved in the form of hydrogen, dis-
persed using smart inter grids and attached to plug-in and zero discharge transport.
Power consumption is a substantial contributor to international emissions besides
climate adjustment. Industry 4.0 permits industrial manufacturers to change to
renewable resources such as solar, wind and geothermal. Renewable energy plays
a key function in the decarbonization of the whole universe. As renewable resource
systems have actually become extra effective, costs have dropped substantially – a
trend established with ideas such as smart metering and smart grids to proceed.
Smart grids supply electrical power utilities, generators and users with the tools to con-
nect as well utilize new technologies has actually resulted in a need for new power gen-
eration modern technologies and batteries, motivating stronger supply chains as well.
Consumers are requiring tidy, environmentally friendly approaches that cut down
on carbon emissions to alleviate power besides energy expenses. Industry 4.0 makes
it possible for have a reliable administration of an abundant yet unpredictable type
of energy generation, supplying much-required stability and integrity. The favorable
persons response to solar photovoltaic (PV) is making the industry more competi-
tive. Solar PV is well on the path toward a levelized expense of electrical power with
the correct application of smart innovation. Solar PV has actually been verified as a
green power resource. The successful model of a monolithic, central power supply is
increasingly being transformed to more flexible and decentralized. Energy collected
from a variety of neighborhood sources is effectively coordinated; it is a lot more
budget friendly, much more reliable and, certainly, greener.
Solar power systems such as solar ranches and concentrating solar power plants
are becoming the globe’s most important energy sources, generating more energy
than other non-renewable fuel sources such as wind and hydroelectric systems, in
addition to minimizing carbon emissions. Manufacturing industries make use of
large buildings with a lot of roofing system areas as they are more suitable for a PV
panel system. Resorting to solar will certainly save a lot on electricity prices while
being shielded against the power price increase.
Many industrial manufacturing enterprise leaders may assume that it is not inexpensive
for small to medium-sized businesses, however, that is not real. As a company that
utilizes a great deal of electrical power to power tools both exterior and interior lights,
machines, and so on, the most effective way to manage the power prices is to locate
alternate power sources, such as the solar power. The sun’s abundant power is an end-
less resource of power that does not damage the ozone layer. Industrial solar power
systems are an investment in the future of the planet that can help to utilize non-renew-
able energy resources and protect the environment. Solar PV production advancements
Transformation in Industrial Manufacturing 89
coming down the pipe are reducing the quantities of costly products such as silicon
used in the manufacture of solar batteries, in addition to innovations such as bifacial
components that allow panels to catch solar power from both sides.
New organization version Energy-as-a-Service (EaaS) is transforming the energy mar-
ket. Businesses with sustainability objectives keen on extracting takes advantage of
power financial savings, partner with an EaaS professional, who possesses a technol-
ogy to assess the power profile of the business with the goal of determining the most
effective opportunities for energy optimization. Power landscape is therefore trans-
formed from being centralized, foreseeable, up and down incorporated and unidirec-
tional, to being distributed, periodic, horizontally networked, as well as bidirectional.
Digital innovations such as artificial intelligence (AI), machine learning (ML),
industrial robots, cobots, Internet of Things (IoT)/Industrial Internet of Things (IIoT)
enable radical workplace transformations, maximizing human–machine communica-
tions and taking advantage of added-value human workers to the manufacturing opera-
tions. Technology progresses around the clock. Utilizing solar power in the automation
industry is a technological change by itself, and industries are lucky to experience it.
Solar energy is paving the way for ingenious and smart-connected modern technologies,
particularly in industrial manufacturing. Solar PV capacity has broadened significantly
as the rate of the innovation has actually dropped; however, the high expense of setting
up stays an obstacle. Emerging SME’s participating in manufacturing solar mounting
structures turns into one of the biggest contributors to the decrease in installation costs.
Process Automation and Transformation in Solar Energy Sector

Increased use of renewables and resiliency problems along with issues of sustain-
ability are just a few factors driving the solar energy sectors’ demand to transform.
Leading industrialized transformation economies Industry 4.0 and Industry 5.0 have
a growing effect on the power field. Generation, distribution, consumption and smart
manufacturing of solar energy are experiencing a massive revolutionary change as
a result of technologies such as IoT, cloud and big data, ML, AI, augmented reality
(AR)/ virtual reality (VR), digital twin, robotic process automation (RPA), indus-
trial robots, cobots, blockchain, and so on. Transformation includes these technical
advances to construct smart grids, to handle renewable energy, to distribute genera-
tion, to recognize usage pattern, dynamic monitoring and customer engagement.
The main question that occurs in our minds is this: why do solar power fields
go for process transformation? Solar power markets rely on renewable energies; the
disruption of COVID-19 has actually forced many to shut down their business, and it
has underscored that the survival of many business depends on the implementation
of automation. Decision makers need to recognize the optimal mix of services with
a suitable, customized technology with those in market and an organization models
along with system operations in an organized strategy.
Automation in Solar Power Plant

Solar power plant has hundreds of connected gadgets from a variety of suppliers
distributed across the geographical area. Making use of a solar electrical PV system,
it is necessary to evaluate just how much energy the system can generate according
90 Industry 5.0
to location, positioning as well as plant conversion effectiveness. Incorporating some

kind of performance monitoring system is important in order to keep an eye on the
quantity of energy being created and to ensure that its responsds quickly when trou-
bles take place. Utilizing a supervisory control and data acquisition (SCADA) system
should be necessary to quickly keep an eye on, regulate and evaluate performanc to
ensure that the projection conversion efficiency, low downtime and fault detection of
a solar PV power plant will continue to be undamaged over its life span.
The SCADA procedure administration is exceptionally reliable with the visual-
ization of real-time data with alarm systems. The interactive program framework for
the simple representation and handling of area-sensing units, actuators and inverters
is a beneficial element. Numerous screens and instinctive navigating on account of
ordered views guarantee SMEs an organized introduction of the system operations.
Advanced SCADA application analytics to the solar PV plant provides useful insight
right into the plant performance. Providing these data visually utilizing graphs and
reports on intuitive control panels helps to make the best use of efficiency as well
as rundown details. SMEs can commence the automation journey with a versatile
system by gathering and managing generation information from plant sites; SCADA
systems sustain concerning every facet of a solar power plant.
3D-Printed Solar Panels

Creating new sorts of solar panels is a long process that contains various examina-
tions and models. With enhancements in three-dimensional (3D)-printing PV pan-
els, the modern technology is transforming much faster than ever. Using additive
manufacturing (AM), cells can be manufactured in minutes permitting faster screen-
ing efficiency. Bolt mounting systems are few of the most commonly used products
(hardware) in the solar sector, which is a terrific prospect for AM. In 3D-printed PV,
the panel base is a transparent plastic sheet, set as layers from the semiconducting
ink to the surface area, to create cells that are 200 microns thick, nearly four times
the density of a human hair.
Solar power will ensure that solar manufacturing and shipment will fulfill the
demand of the expanding green energy customers. 3D printing creates extremely thin
solar batteries that can be published on economical products such as plastic, fiber or
paper. Its ability to develop adaptable lightweight solar panels might have a higher
favorable effect on future electronic devices, hi-tech apparel and even vehicle paint
as well as paints used for structures in the form of solar spray.
RPA-Enhanced Solar Energy Sector

Solar energy industry is facing an age of challenges marked by intense competitors,
stricter laws, environmental sustainability, and so on. Thinking about process auto-
mation as the primary step in the direction of Industry 4.0, RPA is one of the most
fully grown segments of the broader arising AI market. Moreover, automation is now
underway in the solar power market, beginning with management and repeated back-
office procedures. Some of the locations where RPA are suitable are accounting,
finance, human resources, audit and administrative assistance for procedures. With
respect to SMEs, opting for RPA needs to start with creating a strategy, based upon
the enterprise’s existing IT strategy, and a high-level RPA process evaluation in order
to confirm an extensive checklist of procedures and create the business situation to

support financial investment.
Integrity, price and gaining back consumer trust drive the solar energy sector. Solar
PV industries increase investments in RPA to improve operational performance through
automating tasks, thereby helping to cut energy procedure expenses. The course to
RPA ought to be a plan to grow business, incorporating AI with RPA as an important
enabler. Both the innovations have the possibility to raise the precision of jobs, to reduce
the labor strength of work, to carry out new analyses enabled by the ability to process,
and to connect complex datasets. Decarbonization, deregulation and decentralization
impact solar power market by allowing AI and RPA in managing the equilibrium in
between demand vs supply, thereby improving efficiencies in all the entirety of the
value chain, altering the consumer experience and changing service versions.
Incorporating AR in Solar Energy Sector

The AR lays over electronic details, straight or indirect sight of a physical, real-world
setting; here, the elements are increased such as 3D versions and video clips, upon
the real world through smart devices or AR glasses. Application of AR in the solar
power sector has substantially benefited staff member safety along with property
protection. Data analytics gives workable insights, and AR makes the data offered to
the individual appropriate for making organization decisions.
Solar cell functions are common throughout; the capacity to imagine how systems
look on industrial buildings before purchase is becoming vital for solar panel distrib-
uters. The operation and maintenance team, along with the engineering; procurement
and construction team; and the asset management group are able to quicken existing
operations as well as reduce the expenses too while boosting safety during the field
operations. It assists to generate efficiency in staff member training, conduct faster
upkeep activities and provide functional safety and security. AR, VR and mixed real-
ity are removed in a huge method and bring in new worth to the energy sector. The
enterprise is ripe for interruption from AR, which guarantees to make workflows a
lot more reliable, effective, safe and productive. With AR systems having actually
reached a budget-friendly price factor, these options that enable knowledge-sharing
and make work environment productivity tools are excellent opportunities for SMEs
to invest on the technological front.
Impact of IoT on Compact Linear Fresnel Reflector (CLFR)

Solar power plant is becoming a significantly practical alternative for energy manu-
facturing as typical power generation is becoming a whole lot costlier. Of the solar
power plant innovation, CLFR is developing rapidly. CLFR is a sort of solar energy
collection agency. It uses degree mirrors as opposed to allegorical mirrors that are
used in solar parabolic troughs. The basic concept continues to be the very same with
the mirrors collecting solar energy that creates vapor, which consequently drives a
turbine. This modern technology leads to the manufacturing of vapor and not mak-
ing use of warmth transfer liquid or any other medium. The sunlight that is concen-
trated with the aid of mirrors boils the water that is existing in the receiver tubes
consequently creating heavy steam. No heat exchangers are used in this system.
92 Industry 5.0
Solar plants are metered in real time to determine their basic earnings; particular
panels within a ranch are typically not checked. With the growth of the IoT, it is feasi-
ble to affix sensors to particular PV panels in a solar plant. The countless advantages
contain granular real-time standing monitoring, real-time modification and likewise
preparing for analytics. Overall, IoT will definitely improve the performance of solar
plants in addition to making them much more available. Particularly, sensors will
definitely enable solar energy plant supervisors to identify problems with informa-
tion panels along with the layers of an IoT system.
SMART Solar Power Plant

If one is thoughtful about making use of solar energy for the industrial complex or
the factory’s power needs, two major points need to be considered prior to establish-
ing solar energy: the solar meter connected to the solar energy system that checks
how much electric power the system sends into a battery and the grid monitor that is
a vital part of the solar power system that helps to monitor the battery levels by mak-
ing use of a battery meter. Traditional solar power panels need to be monitored for
ideal power result and lack the capability to determine; additionally, they take care
of breakdowns in real time. With lasting energy systems instrumented, there are a
variety of sensors used next to IoT-enabled networks, where a considerable amount of
data is gathered besides being reviewed, consisting of PV panel temperature settings
and extra opens up a brand-new standard to really feel, act, present and handle any
element in a digitized environment.
As the digital interests of energy firms escalate, the need for improved connec-
tivity to remote areas and the improvement of new ingenious Industry 4.0 technical
usage is enhanced. By connecting the IoT with the solar energy system, energy pro-
viders handle each of the solar panel tools from one major control board that helps to
recover reliable power end results from solar energy plant while looking for damaged
PV panels, connections, dirt collected on panels and various other such problems
that can impact solar efficiency. IoT helps link all the elements of power production
in addition to consumption; it aids in gaining visibility at the same times supplies
authentic control at every stage of power flow from usage to the supply throughout.
Participation of IoT in the solar power system helps in monitoring solar plants as well
as ensures ideal power result from another location dynamically. There is a lot more
to solar than solar energy monitoring tools.
AI Application in Solar Energy Sector

AI and ML have the potential to evaluate the past, enhance the present and forecast
the future. Boosted projecting and scheduling of power sources become important
for the renewable energy industry in order to efficiently manage the grid. By integrat-
ing AI into the solar power system, sensing units affixed to the grids collect a big
amount of data that provide useful information to industrial maintenance operators
to provide higher control as well as adaptability to smartly readjust the supply with
demand. Smart storage units can additionally be changed based upon the flow of
supply. In addition to this, making a prediction about weather condition with the help
of smart sensors and advanced sensing units will improve the overall assimilation
and performance of renewable energy. In a nutshell, AI offers far better prediction

capacities making it possible for improved demand forecasting and managing assets.
Its automation capacity drives the functional quality leading to competitive advan-
tage and increased financial savings for stakeholders.
One of the industrial examples is sophisticated load control systems set up with the
machine, such as industrial furnace, which can automatically turn off when the power
supply is reduced. An additional instance autonomous drones with real-time AI sup-
ported evaluation will certainly come to be reliable and also effective analysis of pho-
tovoltaic panels.
(Gligor et al., 2018)
AI applications can transform the renewable energy through boosted efficiency, which
consequently will sustain the growth of the industry and ideally accelerates its fostering.
Applying AI to the advancement of new products can decrease ingrained discharges,
poisoning and costs. One of the most crucial variables to be taken into account with
renewable energy is the reality that nature is unpredictable. Innovative technology is set
to influence every part of a solar energy utility’s operation. If used wisely, AI can become
the most effective possessions paving the path to a cleaner and greener environment.
EXTRUSION PROCESS INDUSTRY

The introduction of smart cities, smart structures, transforming way of life, and so
on, are a few factors that have actually given a rise to a new structure of modern
technologies and products. The plastic extrusion procedure includes melting plastic
products, requiring it into a die to form it into a constant profile and after that cut-
ting it to size. Plastic extrusion is utilized to generate a large range of products across
the industrial sectors, such as constructing products, commercial products, industrial
components, armed forces, medical and pharmaceutical sectors. Pipelines, automo-
tives, sports, window structures, electrical covers, fences, bordering and more are
simply a few of the common things made by plastic extrusion. It has become a great
selection for applications that need an end product with a continuous cross section.
Plastic extrusion is one of the most extensively used production processes for the
creation of plastics.
Every step in the extrusion procedure is essential for a specific quality of the end
item. Product design groups need to begin considering extrusion needs while con-
ceptualizing in the concept stage. Having an extrusion professional on the NPD team
and participating in the brainstorming during ideation will enhance the conception
process. The art of extrusion trusts experience and comprehensive quality control
utilizing the right temperature level, speed, pressure, tension and time elements to
develop a consistent product. Medical device manufacturers (MDMs) continue to
make smaller, progressively intricate tools with unique geometries that need high-
precision extruded components; effective shared interaction throughout the design
phase helps the tool manufacturer to completely understand what is feasible and addi-
tionally offers the extruder a deeper understanding of the MDMs’ assumptions and
clarifying them with FDA’s governing conformity.
94 Industry 5.0
Medical plastic extrusion is one among the effective techniques for changing the
attributes of raw plastic utilizing a mix of ingredients. Medical procedures entail
the transfer of liquids to or from the patient and employ a wide range of flexible
tube products. Products used in medical plastic extrusion array from polyvinyl chlo-
ride (PVC) to polyurethanes to nylon copolymers to polycarbonate to polyether ether
ketone (PEEK) to silicone. Its application includes catheters, syringes, dental tools,
analysis instruments, drug shipment devices, implants, clinical bags and medical
instruments. Extruded clinical items require the cautious application of precision
handling ideas, specifically for microbore, coextruded or cross-head extruded tubes,
for which the size resistances can be as tiny as ± 5 µm. Medical devices continue
to need small-sized tubes with accuracy becoming increasingly important. The
extruded medical tool design is categorized as tubes with solitary profiles, multilu-
men profiles, films for item packaging, sheets that can be post-formed into liquid
containers, catheter tubing with encapsulated striping, multilayer tubes, films and
sheets. Getting over new product design challenges needs to be a collaborative pro-
cedure between the MDMs and the extruders.
Raw material plays an important role in the plastic extrusion industry. uPVC also
known as rigid PVC or vinyl siding or vinyl is among the most flexible and sustain-
able materials utilized in the construction industry. As it is totally free of Bisphenol
A (BPA) means that uPVC can be used in medical as well as in dental equipment
without the worry of contamination. State-of-the-art flexibility makes uPVC a per-
fect selection for windows and doors used in business, factory and domestic func-
tions. uPVC doors and windows give reliable, effective thermal, audio insulation
and help in energy preservation. Unlike timber and lightweight aluminum, uPVC
maintains its shape in all weather conditions and stays unrestricted in case of any
type of physical effect. uPVC is often utilized in dental retainers for its strong and
non-toxic attributes. Growing popularity and demand for uPVC doors and windows
have provided chances to numerous SMEs to endeavor into this industry.
Statistical Process control (SPC) is crucial in comprehending procedure capacities,
recognizing unwanted variations, refining manufacturing procedures, and it allows
enterprises to effectively and constantly fulfill customer’s sophisticated demands for
high quality, preparation, tolerances, distribution, as well as cost. Reviewing soli-
tary process variables one by one is called as univariate evaluation, and it does not
capture every one of the variables and communications influencing the high quality,
whereas reviewing greater than one variable at a time is called multivariate methods.
Multivariate data analysis (MVDA) has actually become essential for the continuous
enhancement and upkeep of operational reliability. It is a statistical procedure for the
evaluation of data including more than one sort of dimension. MVDA techniques
are progressively being utilized for a range, and batch-to-batch contrast examina-
tions to support and derive procedure understanding, which inevitably enhances the
quality, security and effectiveness of medication components. With regard to the
plastic supplier process, set points are marked within the procedure home window,
and the robustness of the process can be checked by altering one process variable;
depending on the initial settings, such examinations can bring about various process
restrictions. Recognition of robust process setups is best completed with the design
of experiment (DOE) strategies. DOE is an organized, efficient approach that at the
same time investigates multiple process elements making use of a minimal num-
ber of experiments. Effective use of DOE can help with the advancement of models
through making use of robust approach multivariate analyses.
The extrusion process is advancing together with the smart technological inno-
vation. Sharing knowledge of how extrusion influences device manufacturing is
critical to make intuitive choices that will ultimately reduce the time to market. The
business model for industrial advancement offering innovative product designs,
manufacturing and control solutions is Industry 4.0. One common variable across
different industrial sectors is the transition to a green economy that will certainly
have a global influence. SMEs’ and OEMs’ priority concern is about the depen-
dence on plastic and its environmental effect. Plastic usage during COVID-19 pan-
demic has caused a resurgence. The process industries along with various other
production sectors must strictly dedicate to environmental, social and corporate
governance (ESG) plan focussing on waste generation management and reducing
the damage on the ecosystem. Utilizing AI options with environmental manage-
ment will certainly pave the way; the absence of strong emphasis and activity leads
to the demand for a better technological option to conserve the atmosphere and
increase sustainability with Industry 5.0.
Process Automation Potentials

A great deal of idea and process goes into making the uPVC profile, starting from the
layout to the packaging. A uPVC profile is engineered to precision with all the life
elements kept in mind. The fundamental part is the choice of the raw materials and
the temperature they are being extruded. Three distinct stages associated with the
uPVC manufacturing process are the formation of the material substance, extrusion
of uPVC accounts and packaging and distribution. Applying Industry 4.0 to uPVC
extrusion processes permits the assimilation of vendors and consumers along with
the close interlinking of internal departments and procedures. Transformation of
uPVC extrusion process to end up being an extremely specific fabrication procedure
has actually continued thanks to Industry 4.0 and its allied technologies.
The uPVC extrusion is a continual processing approach that offers high-speed and
high-volume production with the capability to develop profiles of differing forms,
thickness and shades. Due to the complexity of the extrusion process, issues will
eventually occur. It consists of raw material mixers, extruders, pass away, vacuum
calibration systems, pullers, cooling systems and haul off. Each section of the pro-
file extrusion procedure itself can develop one-of-a-kind troubles, leading to poor
extrudate high-quality turns down. Some of the areas where process automation can
be applied resulted in high effective operations, less wastage of raw materials, less
rejections of profiles, energy efficiency, and so on as follows:
Real-time monitoring of information such as
• Raw material consumption

• Energy consumption
• Heating zone efficiency
• Temperature stability.
96 Industry 5.0
Thus, helping technicians take immediate action and allowing managers to monitor
operational costs in real time.
• Construction of a digital business model of the production process

• Energy monitoring
• Process optimization
• Online quality monitoring.
Process Automation to Transformation

Swiftly proceeding variables within the sector of plastic extrusion systems is the
solution mode dealing with recycled plastic extrusion systems. Handling plastics
clearly represents one of the most fragile stages in the worth chain, whether it is
plastic molding, transforming, extruding or brightening surfaces. For the plastic
molding industry, automation certainly does not result only in the automation of
human workforce. The objectives of automation in plastic molding operations are to
increase performance and savings. Technologies such as simulation, IoT/IIoT, data
analytics, big data, AR and AM would certainly be relevant for process automation
to transformation in plastic extrusion industries.
Updating the digital control systems permits better precision and uniformity
throughout the high-quality production process with less wastage, and maintaining
the temperature level consistently is vital to a successful plastic production process
that creates top-quality items. The main parts of an extruder manufacturing process
consist of a receptacle, barrel, screwdriver and electric motor. The second part is the
raw polycarbonate material planned for extrusion. The last part needed for plastic
extrusion is the die, which functions as the mold for the plastic extrusion. Heaters
must be monitored, decreased, elevated or shutoff as required to maintain consis-
tent warmth within the extruder, cooling fans and cast in heating system coats can
additionally help preserve appropriate extrusion temperature levels. Enterprise deci-
sion makers worry about both their labor force and fulfilling the expectations of the
customers; besides, they need to be mindful of the pressure that repetitive, non-value-
added work puts on their employees.
Simulation in Optimizing Process Flow

Extrusion procedure is just one of the most essential manufacturing methods for creat-
ing ceramic, glass and polymeric products. Manufacturing has been performed based
on empirical experience and trial-error techniques. Application of extrusion proce-
dures is specifically prevalent in item manufacturing that makes use of polymers as
the basic material. The temperature-level distribution inside the die alloy, in addition
to the geometry of the flow channel, has considerable impact on the circulation behav-
ior. Simulation is an effective means of checking out rheological defects, assessing,
improving a procedure, positioned in the hands of the product and computational fluid
dynamics (CFD) for engineers early in the product development life cycle as it allows
very easy exploration of alternatives, delivering an improved end item, decreased scrap
and tooling revamp costs. Simulation assists to determine dead spots, excessively long
house times in the die and high pressure losses before the die is constructed. It enables
optimization and design exploration to decrease waste and overdesign.
To anticipate behaviors such as fluid characteristics and mechanical stress,

based on existing designs for the shaped parts, simulation helps SMEs to digitally
mimicking virtually every element of the production procedure, from material
circulation to coolant distribution to contraction and warpage of the molded part.
Moreover, it offers guarantee for any plastic part developed for manufacture by
stabilizing product efficiency in regards to toughness, rigidity and exhaustion life
with minimum cost production. Development in simulation enhances and forecasts
the development of the plastic melt front in addition to predicting and gauging
the last shaped form with other specifications such as filling-up, analysis, warp-
age estimations, thermal optimization analyses and choices for customizing its
product data source. Carrying out a mold flow simulation permits NPD groups
to conserve time during the growth procedure, cutting prices significantly and
attaining monetary benefits that are passed onto the organization. Computer-aided
engineering (CAE)/CFD tools integrated with AI compute variants in the molding
process beforehand.
AR Scope in Plastic Industry

Plastic industries are in the process of presenting themselves modern technologies
to accomplish zero-defect production and improve work cell versatility. AR modern
technology progressively expands its outreach by establishing its presence through-
out various industrial fields. The key advantage of AR as opposses to other Industry
4.0 technologies is that it is very easy to test. AR is readily available and is budget-
friendly for SMEs. AR projects are generally very easy to implement, and the sys-
tems on the marketplace use common plug-and-play methods that are reasonably
simple to integrate into the enterprise’s application ecosystem. One of the toughest
challenges is knowing exactly how to integrate the pressing need for development
with the ability of humans to adapt to something new. There are also lots of superior
technological obstacles; the largest obstacle in bringing AR into the business will
certainly be organization transformation. AR provides brand-new ways of interact-
ing with manufacturing, product designs and machines.
AM Advances Plastic Manufacturing

The need for AM is enhancing day after day due to one-of-a-kind features as well as
competitive advantages. Moreover, in the world of plastic molding manufacturing, 3D
printing or AM plays a considerable function. One of the primary advantages is that it
gives an eco-friendly plastic manufacturing approach that creates a product with min-
imal waste. Medical and dental items are regularly tailored to the specific using 3D
printing. Machining the part from aluminum is a practical choice, and with 3D print-
ing, one is able to effectively deliver polymer components in low amounts. Steel will
not be the product of option, carbon fiber-filled 3D-printed polymer can replace even
a tough or solid steel. Adopting commercial 3D printers to accelerate NPD by proto-
typing internal part is just a short leap away. With increasing manufacturing prices
and the digitization of manufacturing, industrial manufacturing OEMs and SMEs
continue to inconsistently evolve to keep functional dexterity, to keep costs down and
consequently increasingly looking to 3D printing to remain dexterous, receptive and
ingenious. While considering medical device segment, the geometric freedom guar-
anteed by AM and the capability to supply more personalized individual treatment
98 Industry 5.0
cost-effectively is widely enticing. When paired with CT scanning, 3D printing is

used to offer patient-specific services, such as implants and dental appliances.
Environment Management System

Carrying out an environment management system (Ems) in plastic industries will
certainly aid to determine, analyze and take care of the ecological effects of the
operations. Plastic is among the most favored materials worldwide. Plastics market
ventures are confronted with a variety of challenges daily, and also, preserving the
highest level of quality in their operational processes and products is a must. SMEs
and OEMs of plastics industry swiftly see a return on investment when they discover
and execute in conformity to the demands of ISO criteria for quality administration,
security and environmental management. One such criterion in ISO 14001 focuses
on the environmental effect that the activities.
An Ems focuses on waste minimization and reducing financial expenses from
decreased waste, scrap, rework and energy usage. ISO 14001 does not state demands for
ecological efficiency yet draws up a structure that an organization must comply with to
establish an effective Ems. A solid commitment from the executive management level is
important to ensure the effective implementation of an Ems. An initial review followed
by gap analysis of the business process and products developed is advised, to help in
determining all elements of the current operation and future procedures that might con-
cern the environment. Plastics manufacturing industries that take a close look at their
environmental effect inevitably discover opportunities to minimize waste by regularly
generating substantial waste reusing procedure savings. In addition to enhancements in
performance, SMEs and OEMs can gain a number of financial benefits including higher
conformance with legislative and governing demands by adopting the ISO criterion.
Outcome of Transformation
Industrial transformation in the plastics industry is based not only on global con-
nection but also on the arrangement of derived data along with process and digital
improvement. One of the best challenges for automation industrial manufacturers is
to outfit or upgrade all end consumers for the future and prepare themselves appro-
priately for prospective global industry needs. The idea is that the industry 4.0 sensa-
tion will certainly not stay a fad for the large gamers, but will become a living truth
for small as well as for medium-sized enterprises. Having MES permits automated
real-time precise data evaluation on consumers and materials from different vendors.
MES is the maximized remedy for the SMEs plastics sector for cost-optimized and
reliable link of the machines on a worldwide range.
Process optimization via automation is generally related to a reduction in scrap rates,
downtime and better monitoring of manufacturers for predictive maintenance. Process
transformation means a substantial renovation in the quality and the accuracy of data
gathered and evaluated from machinery via the manufacturing processes. Unforeseen
losses because of equipment disruption or wear down can be decreased with a variety
of technologies consisting of sensors set up to gather real-time information incorpo-
rated with cloud that enables complex data analytics improved with ML. Operational
tracking notifies anticipating maintenance; therefore, significantly decreases the down-
time of the equipment as well as the prospective scrap from the process.
Abundant details derived from big data analytics provide insights as a result of
the digitization of processes; this dynamically strengthens the understanding of the
enterprise to take actions to achieve innovation improvements across the value chain.
Every organization needs to carefully evaluate the advantages and challenges that
Industry 5.0 through Industry 4.0 entail before starting the transformational jour-
ney. Business enterprise teams include environment, health and safety, quality and
manufacturing. The senior administration, must continuously be included to improve
the suitability, competence and performance of the Ems. Improving environmental
performance will add considerable value to the organizations. With the introduction
of Industry 5.0 SMEs, OEMs will be able to find waste creation as an additional
opportunity and can transform waste disposal back into straight revenues drawing a
path to a green and clean ecosystem of the future industrial economy.
GROUND SUPPORT EQUIPMENT IN AVIATION INDUSTRY

Airport terminals broaden their operations, resulting in the enhancement of brand-
new terminals, entrances, traveler solution tools, along with another framework.
Each gateway of an airport terminal calls for ground support equipment (GSE). The
main function of the GSE is to support on-ground operations in between flights while
the aircraft is parked at the gate to accommodate the needs of airplanes. The need for
GSE is directly proportional to the growth of brand-new airport terminals and the
addition of brand-new gateways, terminals at existing airport terminals. GSE is used
to service commercial and military airplanes. Efficient, trustworthy airplane GSE
is the key to guarantee smooth turnarounds and on-time separations thus avoiding
delays, costs as well as trouble for guests. The growth of hybrid GSE, new batteries,
quickly billing ports and improved electrical ground support tools with reduced
maintenance costs is underway across the globe.
The main stakeholders in the GSE industry ecosystem are enterprises that s upply
lasting air travel gas, SMEs, modern technology providers, suppliers, providers,
retailers and end consumers. The key ground power units (GPUs) of the GSE are
battery-driven eGPUs, electricity-driven GPUs and diesel-driven GPUs. Considring
the Ems, the battery GPUs and the electricity-driven GPUs are regarded as cleaner
and greener whereas the diesel GPU leaves a large carbon dioxide impact. The
Industry 4.0 technical era has the potential to boost GSE air transport key efficiency
locations, where safety levels are so high in spite of the margins for enhancement
being incredibly tight. The Industry 5.0 era could imply a change in safety improve-
ment through maintenance, repair and overhaul (MRO). The successful delivery
of airport terminal operations needed competent ground managing staff and GSE,
which has dramatically boosted the need for aviation GSE around the world. Price
has constantly been a variable that influences the selection of GSE manufacturers.

Rate, performance and precision are very important considerations in ground han-
dling for decreasing the turnaround time. Efforts are taken to promote an eco-friendly
GSE such as flight catering hi-lifts, ambulifts, self-propelled traveler step ladders,
100 Industry 5.0
towable step ladders, luggage trolleys, aircraft test engine cells, cleaning trolleys,
fuel browsers, containers and pallet dollys, mobile elevated observation systems, and
so on, at airports. SMEs make use of Industry 4.0 technical development as the first
step in transforming logistics procedures into event-based procedures looking for
offered equipment dynamically to appropriate details such as fuel and temperature
levels, so on to improve customer complete satisfaction besides gaining competi-
tive advantages. Complete exposure in of GSE, for maximizing the ground handling
solutions on the apron. By embedding smart sensing units on the GSE, SMEs will
certainly be able to transform assets into important smart asset monitoring, thereby
maximizing enterprise performance and processes. Time-consuming jobs such as
GSE malfunctions help prevent blackouts and errors.
AR/VR Improve MRO in Aviation GSE

Aviation is a busy industry, and the important way leading airline companies, flight
terminals and cargo business run smoothly is by leveraging the very best available in
aviation GSE. As GSE suppliers and OEMs start to function closely with automated
solutions, GSE training will certainly require to alter and provide the staff with brand-
new understanding and abilities to guarantee safety. There are a few key challenges to
be overcome to construct risk-free and efficient computerized GSE system. The pricey
nature of the air travel industry amplifies the high cost of making errors. AR and VR
are a terrific assets for GSE enterprises to provide a far better service and train the
employees in a more precise means. It has become a game changer for aviation GSE
technicians and MRO professionals to check different parts of the GSE. Industry 4.0
innovations are conserving money and time, boosting operational effectiveness and
assisting to improve the level of service to their clients, thereby making procedures a
lot more effective and improving the efficiency of MRO in GSE logistics.
MRO facility technicians assist to maintain the aircrafts and function securely
and accurately by making use of aircraft ground support devices. Digital twins enjoy
tangible advantages and have been extensively embraced in the GSE production pro-
cess, which experiences modern technology is being fed into MRO. With the advent
of Industry 5.0, GSE SMEs are relocating into more process-oriented worth than asset
administration. Process improvement enables preventative and anticipating upkeep
for GSE MROs, which increases integrity and safety. The dependability generated by
digital twins can include dependability across the whole company value. An impor-
tant channel for the digital twins is the sensing unit. All emerging assets all tend to
have sensors, enabling ease of information that consequently provide insights together
with the application of AI, which will certainly lay the foundation for a lot more accu-
rate and thorough projecting. Digital twins along with AR and VR assist GSE SMEs
to attain complete process transformation and automation. They help enterprises to
do reliable predictive maintenance in the long-run paving course to reduction of costs,
assets monitoring, decrease downtime as well as NPD. COVID-19 pandemic has actu-
ally created an urgent need for the promotion of industrial transformation initiatives.
AM Applied in Aviation GSE

3D printing’s ability is to be adapted to generally anything that the filaments can read-
ily develop. GSE will certainly benefit from AM technology; parts can be replaced
quickly by printing them at any place by any person with a capable 3D printer. It is
reasonable to theorize 3D printing as a sensible prototyping approach for a variety of

elements for GSE models. Manufacturers of GSE can now own the market and gain
access to legal rights to the CAD documents rather than keeping huge inventories of
stock. Reduced weight, lengthy service life, peaceful operation and fantastic robust-
ness are among the most important of those needs. It is possible that a substitute part
could be all set within an hour of receiving the purchase order, rather than awaiting
for gauged in days. It can be used to build full-blown mockups and is conveniently
developed to exact specifications. AM stands to entirely change the GSE market.
Outcome of Transformation
Ground handling is critically crucial to the airline industry market yet it additionally
needs to go for the lowest feasible cost. GSE ought to consider all safety requirements
to be taken into account for the design of aviation ground support tools abiding by the
ISO 6966 standards. Given the governing, ecological and open market conditions, it is
easy to understand that GSE gravitates toward commercial improvement that provides
a much better method to handle their daily operations, while also maximizing their
resources. Smart asset tracking along with administration services aids to keep track
of flight terminal assets and boost the effectiveness of ground handling procedures and
maintenance regimens. GSE SMEs are realizing the benefits as all essential areas such
as telematics data, safety and security, GSE vehicle parking, space usage, discharges
and traffic researches can be better handled and understood with the arrangement
of IoT information. Using electric-powered GPU or solar-powered battery-operated
GPU is a fantastic way to go eco-friendly and remove carbon dioxide discharges.
Appropriate improvement calls for numerous skill sets from radio preparation via
standards growth to IT application with the best team assembled timescales and low
cost. Industrial transformation in GSE sector is about getting rid of unneeded waste
whenever feasible, getting rid of fuel usage, downtime and product waste are wonder-
ful strategies to help accomplish bigger environment-friendly strategy outcomes.
VALVE INDUSTRY
Modern history of the valve sector parallels the industrial transformation, when
Thomas Newcomen designed the initial commercial heavy steam engine that was
subsequently advanced by James Watt, wherein vapor developed stress that needed
to be included as well as managed, and valves got a brand-new importance. Valves
plays a vital function in the high quality of our daily life, such as turning on a tap,
making use of dishwasher, activating a gas pipe, stepping on the accelerator in the
automobile. It is one of the most basic and crucial elements of our modern-day
technical society and is necessary to all manufacturing industrial sectors and every
energy production. Industries that rely on automated valves and tools include the
food and beverage, OEM equipment, oil and gas sector, nuclear sector, petrochemi-
cal industry, shipbuilding, waste management and aerosols. Valves are a require-
ment for almost anything involving the activity of liquids and gases in a closed area.
An additional important element of natural process is in the human heart with four
valves to control the motion of blood via the ventricles, which keeps us alive.
Valves are straightly connected to the operational performance of a manufactur-
ing procedure. It is vital for process designers and well as manufacturers to use a
102 Industry 5.0
fresh eye to these elements as their evolving nature to complement the automation
fad. The pipe system is not total without valves. Safety and service life span are the
most important issues in a pipe process; it is crucial for valve manufacturers to pro-
vide premium valves. NPD approaches in valves industry have actually experienced
lots of changes, but the fundamental design process continues to be unmodified.
Industrial valve production procedure is a complex endeavor. Many factors contrib-
ute to its effectiveness: basic material procurement, machining, heat treatment, weld-
ing and setting up. Valves ought to go through extensive examinations to guarantee
appropriate working before the producers hand them over to the end client. Modern
market requires valves that have proven accuracy advantages and reduced labor and
expense. Leveraging automation, which is simulation, procedure designers can fig-
ure out the minimum viable products (MVPs) of valves and examine these services
making use of simulation to lower the time and sources, thereby bringing about the
physical advancement of valves.
Fast improvements in innovation and the capabilities of computer-assisted con-
trol systems in addition to the integration of electronics have created smart auto-
matic valves that has gained favor in the international market. Principles constructed
around the IIoT have actually directed the industrial automation fields, fast foster-
ing and mainstreaming of several manufacturing systems. The need for valves from
healthcare and pharmaceutical sectors has increased during the COVID-19 pan-
demic episode. Process improvement and transformation is the most talked topic for
management executives across the process industrial sector to help manufacturers
automate and optimize their core manufacturing procedures and attain enhance-
ments in other operational areas such as integrity, sustainability, safety and energy.
Process safety and security are the prime prospect for industrial transformation.
A valve manufacturing enterprise will be able to keep track of the problem of thou-
sands of control valves in a plant across the Internet by a connected solution based upon
IIoT data collected. By utilizing data to determine very early indications, plants will
be able to keep procedures closer to their optimum specification and arrive at better
decision-making. Adoption as well as application of Industry 4.0 through Industry 5.0
required to get rid of a variety of functional and organizational obstacles, in many cases,
because of the lack of modernization and automation in design and manufacturing.

As automation systems became more innovative, advancement in valve modern tech-
nology, performance and flexibility took a significant advance with the integration
of electropneumatic control capabilities right into the valve. It improves valve manu-
facturing facility specifically address dimension and impact, power consumption,
connectivity along with tracking of plant automation as it associates with upkeep
preparation and functional effectivity.
Simulation Support Valve Manufacturing Industry

Valves are usually made for high-temperature liquids as well as gases that could affect
their structural strength, because of too much tension generation and concentration in
restrictive regions. Finite element method stress analysis is implemented to investigate
the tension state of the valve body under numerous loading problems. CFD procedures
recommends a variety of models for circulation speed, density, low-pressure areas
around the bend, impingement angles for wear studies, minimum temperature level
habits as well as chemical focus for any region where circulation happens. Product
engineers design and model the performance of a whole system of pipes and valves
to lower the possibility of failing. CFD simulation assists to check out the failure of
aging infrastructure, providing designers a more exact picture of what had occurred.
When valves manage high temperature of the fluids, the components certainly flaw
under such high thermal stresses leading to the development of splits in the final end
item and leading the valve to fail too soon. Transient thermal evaluation is done mak-
ing use of CFD thermal simulation to forecast the early failure. Simulation assists
NPD participants for a far better valve design optimization. With the development of
AI and ML SMEs, component suppliers will be able to produce a generative design
that can help in designing effective multiple variants of optimized valves.
IIoT in Valve Manufacturing Industry

One of the most important sections of process industry is the control valves. Valve
manufacturers implement IIoT to boost and improve the performance of control
valves and minimize upkeep price at every phase. The function of the control valves
is to regulate procedure variables such as pressure, temperature levels and flow rates
of liquid or gas. All these factors add to the general operational effectiveness of the
process in the shop floor. IIoT links needed sensors that help in finding and man-
aging different parameters of industrial valves in the field operation, which helps
to appropriately keep an eye, regulate and handle the flow rate of fluids and gases
in piping systems. Without a reliable control valve operation, the procedure would
quickly become unmanageable for the operator. For conventional SME manufac-
turers, a much more vital challenge is that brand-new machinery cannot guarantee
the creation of the exact same top-quality products that their customers have been
utilizing for generations. IIoT offers condition monitoring, which helps SMEs to stop
unintended downtime and improve valve efficiency. The evaluation of information
obtained from IIoT-enabled smart valves help the enterprise’s decision makers to
make better decisions and boost the result.
Remote tracking of hands-on valves is another essential segment in process indus-
trial sector. SMEs will certainly be able to achieve this by economical retrofitting
investment making use of industry quality wireless sensing units and IIoT technolo-
gies. Predominantly manual operated industrial valves controlling large networks of
process pipelines remain in massive use in chemical process sectors, paper industry
and water drainage treatment plants. Generally, these kinds of sensing units are used
for regulating the valves as commercial wireless valve placement sensors (angular
placement sensing units and linear placement sensors) and detector sensors. The sen-
sor gadget then reports the placement information in a digital layout to the SCADA
main control system with field instruments, which will certainly be kept an eye on by
dynamically using an IIoT system. The transformation of procedure control valves
takes long period of time to roll out, due to high retrofitting investments. The enter-
prise enjoys the transformation benefits converted into cost savings, far better secu-
rity and continual procedure optimization.
104 Industry 5.0
IIoT allow industrial valve production users to gather and also keep information from
mostly all assets at an extremely high frequency and also at exceptionally low cost,
which enables effectiveness in work besides business procedures additional to DCS
and PLC. SMEs, component manufacturer and OEMs able to monitor the levels, tem-
peratures, usage, waste, OEE and predictive upkeep data making use of IIoT. The IIoT
platform gives boosted visualizations which allow operators to see modifications in the
system together with atmospheric change much faster than usual.
(Reynolds, n.d.)
Third industrial revolution brought innovations in hydroelectric power industry and

began incorporating information and communication innovations in its power plants
and power grids, where automation along with digital governing controls began to
form. With the onset of Industry 4.0 and Industry 5.0 across the globe, there is an
enhancing requirement for eco-friendly plants aligning with IEC 61850 power plant
automation control standard and an increasing variety of energy sources, both renew-
able and non-renewable. Of which hydroelectric power is an attractive type of energy
because of its reduced carbon emission, affordability and, of course, the wealth of
water. As with any energy generating procedure, control and surveillance software is
a vital way to keep plants controlled. DCS permits the facility to constantly recover
and analyze plant efficiency information, checks key performance signs, provides
workable details for plant employees and provides necessary information when
required in real time. Measurements of temperature, pressure, resonance and other
parameters occur at localized sensing units, which are transformed into time wave-
form signals and examined by the plant operator. Power plant engineers have the
alternative to keep track of the overall system condition and assign sources to deal
with concerns as they are predicted and prior to part failing. The IIoT platform got
in touch with SCADA, and PLC assists to readjust device parameters to maximize
the results. By implementing IIoT, the hydroelectric industries will maximize their
upkeep procedures, cut costs and strategies.
SUMMARY
Process transformation in the process and industrial manufacturing industry through
real-time monitoring and optimization of control valves, lead to efficient upkeep
processes, elimination of unstable manual treatment, far better employee safety and
security and reduced production costs. Industrial transformation is changing the
method organizational leaders assume and how they collect and utilize information
to optimize procedures. Automation innovation is much more sophisticated than
anything that has preceded; robotics and automation systems are coming to be anti-
quated and can present safety and security concerns. AI and robotics, in cooperation
with brand-new innovation like 3D printing, show advantages in bringing advance-
ment in production and satisfying raising consumer demands. Data analytics make
possible for suppliers to pivot from preventive to anticipating maintenance. The mix
of traditional process control systems and new technological innovation is the foun-
dation to improve the accessibility of details besides boosting decision-making. To
stay competitive, enterprises need a system that will certainly manage the needs of
clients, suppliers, management executives and other stakeholders in a seamless way,

which will certainly be enabled by Industry 4.0 via Industry 5.0 that is readied to
take root across the process and industrial manufacturing community. SMEs, OEMs
and part manufacturers take the effort to recognize and harness the power of process
automation as well as process transformation to stay on the zenith of the new digital
era. Industrial transformation is a great journey where the processes and industrial
manufacturing sector advancements become ingenious, flexible, data-driven and step
into the future eco-driven industrial economy.
BIBLIOGRAPHY
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7 Upgradation of Industry
4.0 to Industry 5.0
Industrial transformation and its technical advancement offer us a brand-new para-
digm in manufacturing across different industrial sectors. Industry 4.0 has gained
ground; many manufacturing enterprises comply with the path in the direction of
process automation by means of digital improvement throughout the extended manu-
facturing processes. Customer expectations, the advent of smart connected machines
and systems are driving the continuous digitization of production. Industry 4.0 has
allowed manufacturers to increase operational visibility, reduce costs, quicken man-
ufacturing times and deliver phenomenal client assistance. The onset of the COVID-
19 pandemic has made business tycoons continue to embrace modification in order
to keep ahead of competitors and win market share in an ever-developing industrial
transformation. Manufacturing enterprises that measure their agility and automa-
tion degrees, for instance, could discover that given their degrees of manual work,
these are the remedies they should concentrate on now, whereas their time-to-market
modern technologies still serve them fairly and nicely. Industrial transition across
various industrial sectors is complicated, regularly advancing at a breakneck rate and
will certainly present the enterprise with new challenges that start with defining the
major service requirements, the difficulties to fulfilling those demands, the potential
services to fix those challenges and that need to evolve the industry from current to
the future state. As the market goes on, the value chain develops with it and continues
to remain in steps with updates and brand-new forecasts.
BUSINESS NEED FOR INDUSTRIAL TRANSITION

Modern industry has actually seen significant advancements since the start of the
industrial revolution. To compete internationally, it is essential to embrace the evolu-
tion of technology and recognize exactly how to harness its power to enhance busi-
ness operations. To start, it is essential to comprehend along with details the direction
they are heading to. Manufacturing enterprises can build on their existing methods
and technologies can make them more powerful with the help of Industry 4.0 inno-
vations. Making use of these opportunities calls for substantial financial investment.
A clear business strategy will certainly be essential to obtaining support from stake-
holders, thereby safeguard the required spending plan. Initiating an organization
transformation approach enhances the possibilities of prospering in this new digital
age. Manufacturers ought to not consider digital transformation as an expenditure,
but instead a revenue; enjoying long-term objective will improve the operational
effectiveness along with productivity.
In addition to organization transformation, fully committed management exec-
utives who are accountable for the digital transformation and the integration of
DOI: 10.1201/9781003190677-7 107

108 Industry 5.0
brand-new items, systems and solutions are important. Without the ideal manage-
ment, the reform initiatives might be obstructed. Technical innovation plays a tre-
mendous role in obtaining a competitive advantage in a moderated industrial sector
and thus must be recognized to be a force that drives industry competitors. Customers
nowadays can shop around and often compare the local products with their global
counterparts; this affects the SMEs who find themselves among international com-
petitors even if they do not import or export items or solutions. This has of course a
massive influence on an enterprise’s approach in order to stay ahead of the interna-
tional competitors. To access the impact of globalization, the manufacturing enter-
prise has to comprehend that there is absolutely nothing like one consistent means
to determine it. Instead, several approaches in the direction of gauging globalization
have actually been developed over time.
Considering the degrees of inventiveness, it is also essential to recognize what
the driver of inventiveness generally is. As the product lifecycle reduces, companies
have to act when necessary. Technology is a driving force for generating business
value rather than simply playing the sustaining role. Consequently, enterprises had
to enhance their rate of innovation, which has led them to pursue new services and
product developments faster than ever before. For manufacturers, the concept of the
smart manufacturing facility of the future is becoming true; besides, those hesitant to
accept these advancements are discovering it hard to disregard. To obtain an under-
standing on how to boost the process together with operation standardization and
comprehend where to purchase terms of technology, the business enterprise needs to
recognize their weak points along with their business process factors.
The manufacturing industry’s decision contemplate the future industrial change.
Industries across the globe are transforming quickly, the enterprise's decision-makers
are driven by the need to remain ahead of their competitors and face two essential
questions: Do we have an option to embrace or not embrace the transformation? How
long can we wait before transforming? Actual transformation is only just when the
typical means are tested and the new path is complied with. Operating in repeti-
tive processes, beginning small and scaling up is crucial for success. Considering
the COVID-19 pandemic, it is an ideal time to pursue the industrial transformation
journey from Industry 3.0 to 4.0 to 5.0, taking into consideration safety, environment,
health and wellness and revenue.
CHALLENGES IN INDUSTRIAL TRANSITION

A common adage says with great opportunity, there comes great challenges.
Industrial shift continues to transform the methods of SMEs and original equipment
manufacturer (OEM) across the world, and brand-new challenges occur. For manu-
facturers, efficiency is vital and the point of discomfort comes in several forms. Most
of the manufacturers rely upon breakthroughs in automation on computers and elec-
tronic device-aided innovations; information and communication technology (ICT)
assist to gather, assess and give helpful information in the real time to the production
systems. Industrial transformation is changing the way goods are intended, designed,
manufactured, serviced and made environment friendly. Applying advanced modern
technology in an existing production system, the economic evaluation and return
Upgradation of Industry 4.0 to 5.0 109
of investment (ROI) along with the return of value (ROV) requires to be evaluated
extremely carefully. The threats connected must be computed and taken seriously.
Workers need to acquire brand-new collection of skills to fill the void to pursue
improvement. Pressing research and development in such fields are also important.
So, the additional investment that needs to be made to take on the more recent mod-
ern technology would certainly be compared with the losses in production during an
upgrade along with the time obtained to recover the ROI with the earnings within
existing system that affects the adaption of newer modern technology.
The main challenges are the unstable market demands, the need for better and
faster manufacturing procedures, margins that continuously reduce and intense com-
petitions in between companies that no organization can win without the help of smart
connected innovations. Many sophisticated manufacturers are currently leaning on
multiple traditional data systems such as enterprise resource planning (ERP), mate-
rial requirements planning (MRP), manufacturing execution system (MES), product
lifecycle management (PLM), supervisory control and data acquisition (SCADA),
programmable logic controller (PLC) and Robots. Solutions that allow the seamless
integration of the data systems are the trick to attaining success. The crucial concern
that develops is the ideal means to measure key performance indicator (KPI) or the
success matrix of the industrial transformation. A massive number of data are gener-
ated from different machines in the shop floor, so recognizing how to leverage par-
ticular data for the enterprise or certain KPIs are vital when on identifying the ideal
technological tools that suit the business goals itself difficult. To conclude, manufac-
turers need to produce an out-of-box retrieving strategy to manage failing situations.
The ever-changing fast pace of industrial cutting-edge technologies will certainly
encounter lots of brand-new obstacles and will certainly continue to evolve in time.
MITIGATION OF INDUSTRIAL TRANSITION CHALLENGES

Manufacturing enterprises that emerged as success stories in the third industrial
transformation are the ones that strongly welcomed change, faced the threats, recog-
nized as well as properly embraced the favorable innovations triggered by the perti-
nent drivers and developments seen around them. It could differ from OEMs, yet can
be a vision for SMEs. As a mantra begin of with examining enterprise existing state
of maturity followed by identification locations where to boost maturation efforts,
which lays the structure for successful initial action in the direction of change. For
SMEs, Industry 3.0 values is a great place to begin, starting small helps limit anxiety,
promote adoption and secure management executives buy-in which is another land-
mark in this stunning transformation journey. Few SMEs lack resources to assess
the technical maturity of the pertinent technology as well as their service uses. Some
SME management executives lack a systematic method of application. In order to fill
the ability gap, the SMEs need to, develop and discover programs that support and
integrate new concepts with hands-on possibilities that transform their manufactur-
ing procedures and domains. Keeping an eye out for the smooth assimilation of the
traditional applications with the upgraded modern-day technology is necessary, so
that everything rolls under one solitary structure without affecting the major business
process. Integration can take care of automating existing manual tasks and processes.
110 Industry 5.0
Industry 3.0 Industry 4.0 Industry 5.0
1. Seamless data flow between

1. Agile and Automated engineering and manufacturing
2. Mass Customization 2. Mass Personalization
1. Design 1. Rigid and Manual
3. Smart Connected 3. Custom and Tailor-made
2. Operations 2. Mass Production
4. Factory at distributed 4. Factory at distributed Locations with
3. Product 3. Standardized
Locations involvement of Collaborative Robots
4. Regulation of Factories 4. Factory at Centralized
5. Planning based on Dynamic 5. Planning based on Dynamic and
5. Supply Chain Locations
and Predictive Predictive enhanced with AI
6. Success Metrics 5. Planning based on Inventory
6. High return and value on 6. High Speed and accuracy in
7. Client Relationship 6. Low cost, High Efficiency
capital employed Automation with human touch
8. System 7. Low and Indirect
7. High and Direct 7. High and Direct
9. Benefits 8. Automation with the
8. Cyber Physical System (Data 8. Human Cyber Physical System
utilization of computers
Driven) 9. Increase in Engineering Process
9. Automated process using
9. Reduce Direct Human along with Operation effectivity and
PLC and SCADA along with
Interaction, Better Equipment efficiency. Reduction of
information technology
Forecasting, Increase Line raw material wastage (Zero
Productivity waste),Proper utilization of
renewable energy sources. Utilization
of Unskilled labors
FIGURE 7.1 Transformation journey based on different factors.
The first expedition phase is necessary and when carried out with the ideal focus
can bring about clear and concise final thoughts. Information administration clears
up possession, and privacy. Data exchange between businesses makes it possible for
third parties to acquire an understanding of the organizational techniques; so, it is to
be cleared as to whom the created information belongs to as well as who is qualified
and exactly how to use them. Take a look at the options to executed and adhered to the
team capacities of the internal group or keep an eye out for the vendors’ capacities to
service the requirements. Create a durable system architecture prior to the execution
that stabilizes information technology (IT) demands and the storage area whether
cloud or in-house storage space. Production line operators need to be more involved,
along with cross-functional team (CFT) of new product development (NPD)/new
product introduction (NPI), the ICT team, and the management executives have all
the essential details for higher responsiveness, liability and possession, thus making
complete engineering to manufacturing supply chain presence.
Manufacturers practice to take into consideration business value innovation and new
revenue streams as they utilize the deluge of data produced from innovative modern
technologies. Cognitive devices and sensors are integrated to the production line physi-
cal systems by incorporating the capabilities of Industrial Internet of Things (IIoT),
big data, 3D printing, analytics augmented reality (AR), virtual reality (VR), artificial
intelligence (AI), machine learning (ML), cobots and human knowledge serve busi-
ness functions. Human involvement is typically needed in previous, existing as well as
future industrial transitions. Communication between human intelligence with comput-
erized systems is anticipated to take manufacturing to new levels of optimization and
automation. New abilities will certainly be called for in the locations of smart systems,
robotics programs, new arising innovations and creativity. The essence of Industry 5.0
is applying innovations in the industrial sectors to accelerate their efficiency and not to
replace the humans. The application of industrial transformation in modern technolo-
gies guarantees effectiveness, and optimal performances will be attained with minimal
impact, influencing both the leading and bottom line of organizations.
INDUSTRIAL TRANSITION STRATEGY PLANNING

Industrial transition is so disruptive to standard business models and traditional con-
cepts of industry competitors. Assess the situation of a business enterprise by look-
ing into its structure that assists industrialist and entrepreneurs shape their approach
toward success. There exists many helpful strategies management planning tools for
SMEs to stay one step ahead of their competitors in this smart global industrial sec-
tor. Modern cutting-edge innovations are currently the factors driving business pur-
poses as opposed to just playing a supporting duty. Industry evaluation is a critical
component and is developed to assist enterprises to determine how it operates within
an industry. SMEs need to recognize their standing among competitors through
detailed market forces on a worldwide level and to analyze the standing and potential
profitability. It is much better for an enterprise to have a strategy starting with solid
gap analysis to deep dive into the transition.
The secret of establishing an affordable business strategy is to recognize the
resources of the business, identify its crucial strengths and weaknesses and trans-
form areas where strategic changes will certainly cause the best rewards. In the light
of the unforeseen COVID-19 pandemic, SMEs should think about tactical prepara-
tion tools and methods that would have certainly helped them be more versatile when
the situation takes an unexpected turn. Identify the clients and end users and involve
them during every cycle of tactical planning. Ensure that the enterprise CFT is work-
ing toward a single collection of objectives while a different group is working toward
a different set of objectives; it authorizes the strategy is falling apart from the track.
So, the method has to be interactive engaging all the teams. Have an area built in for
calculated positioning, improvisation and recalibration on the quarterly review board
urging workers to contribute ideas for improvement.
Strategy Planning—Internal Factors

Strengths, weaknesses, opportunities and threats (SWOT) analysis is a simple yet
valuable framework for analyzing. SME management groups need to stick to the
foundation; they need to start with an analysis of their present technology and
people capacities, prior to setting expectations. All-natural view of the organiza-
tion is required for starting with the industrial transition. Strengths and weak-
nesses are interior elements, while opportunities and threats are exterior elements.
Typically, it must focus on what is occurring presently versus what can occur in
the future. Industries are running in a very profitable market in an ever expanding
global industrial economy. So, prioritize threats as well as possibilities as a driver
for recalibrating service goals for the future roadmap probably the next one-, four-
and seven-year perspectives. Use SWOT evaluation as part of the risk management
process to check out and carry out techniques in more balanced and extensive way.
Need to find who are the Enablers, Engagers, Enhancers and have answers for the five
W’s and one H as
1. Who is going to be the users? Who is going to be get benefited?

2. What are the factors going to add value to the Business?
112 Industry 5.0
3. Where the information comes from and where it goes into?

4. Why it is required?
5. How is going to add value?
6. When it is going to give ROI and ROV?
Use five Whys technique in the analyze phase to do the gap analysis. Followed by
Planning, Designing, Implementing, Validating and Rolling out.
The SWOT evaluation process is a brainstorming tool for CFT to discuss various
perspectives on the scenario available. Start to craft a method that identifies the com-
petitors to contend successfully in the market. As soon as the four aspects are filled in
business executive planner figuring out exactly how each force can be leveraged into
opportunities and analyze what weaknesses need to be fixed so that they do not impact
the business results considerably. It is an extensive technique for recognizing not just
the weak points and hazards of an activity plan, but also the strengths and possibilities
it makes possible. When accomplishing the analysis, be sensible as well as strenu-
ous. Constant business analysis and tactical preparation are the most effective means
to monitor growth, strengths and weak points. As the claim goes, chance favors the
ready mind via the SWOT evaluation; SMEs will certainly be better prepared. With
these objectives and actions in hand, SMEs will certainly progress in the direction
of completing a strategic plan. Make use of the basic and reliable lean planning for
executing the strategic plan. Lean planning continuously fine-tunes and modifies the
approach while gauging enterprise’s development toward attaining the goals. It is a
very easy means to derive and document the strategy, tactics, baseline and forecasts.
It is everything about results besides handling an organization’s improvement.
Strengths Weakness Opportunities Threats
What I am Bad at ? What I have to Better What I am getting

What I am Good at? at ? Impacted at?
• Reduction in • Reluctance to
change • Process • Cybersecurity
Operation cost standardization • Skill gap
• Downtime and • Integrity of M2M
communication • Data driven • Roll out of
wastage reduction ecosystem technology
• Increase in • Cost of technology
• IT – OT integration • AI assisted • Changing
Operational Predictive, regulation and
effectiveness • Lack of subject
matter expert Quality and MRO market
insights, ESG,
Touchless line
FIGURE 7.2 SWOT analysis of industrial transformation.

Strategy Planning—External Factors

The political, economic, social, technological, legal and environmental (PESTLE)
factor evaluation is utilized for macro-environmental scanning and includes the com-
ponents of PESTLE elements that could have a straight and durable impact on the
enterprise. It provides a bird’s-eye view of the whole setting from several angles
that wish to check and maintain while contemplating a particular business strat-
egy. It serves in all industrial sectors at the strategic, department and examines the
existing and future markets. It also provides a vital input for planning, advertising,
business and organization transformation, NPD/NPI and so on. Enterprises need to
be able to respond to the present and the future legislation and readjust their market-
ing plan appropriately. It transforms the whole earnings’ generation framework such
as taxes, trades and fiscal plans, a federal government might impose around, and,
it might influence the enterprise’s core procedures. Changes and variations to the
rising cost of living, international direct investment, stock markets merged as macro-
and micro-economical elements will certainly influence the firm’s purchasing power,
product pricing, market supply demand and will have resonating long-term results.
Enterprises need to study health and safety that relates to the social and group trends
of the society, which is crucial in identifying the consumer purchasing habits.
Technological transformation opens new doors to technical fads and generates
possibilities for many businesses. Both SMEs and OEMs tend to focus heavily on
the impact of the emerging new innovations. It plays a vital role in the develop-
ment of the industrial sectors beyond advancement in the industrial economy. It han-
dles almost everything namely computer numerical control (CNC) machines, PLC,
SCADA, industrial robots cyber-security smart production equipment AI cobots and
human intelligence. Modern technology is utilized to market, deliver and service end
items. It helps in assessing rival information besides comprehending marketing fac-
tors, complications and the areas to improve. Enterprises need to comply with cus-
tomer laws, accessibility to materials, sources, imports and exports, safety criteria,
labor regulations and need to understand what is legal and what is not legal in order
to trade effectively. Environmental aspects issue the ecological impacts on industry
deal with a scenario such as pandemics, global warming and sustainable sources.
This is a must have requirement and this is vital because of the increasing depletion
Political Economical Social Technological Legal Environm

ental
• Government • Increase of • Cost • Process • Compliance • ESG

Regulations Revenue Reduction Automation • Asset • RoHs
• Foreign • Invest in • Process • Industrial Management • WEEE
Direct existing innovation Automation • Recycle and
Investment resources • Quality • Robots Reuse
• Trading (3M’s) innovation • Digital Twin • Energy
• Taxation • Waste • Health and • Cobots reduction
Reduction Living • IoT / IIoT • Green energy
• Training • AI, ML
• 3D/4D
Printing etc.
FIGURE 7.3 PESTLE analysis of industrial transformation.

114 Industry 5.0
of resources and contamination. It is important to run an industry as a moral and

sustainable enterprise, leaving less carbon footprint targets as set by government
organizations.
The SWOT analysis focuses on an enterprise’s inner strengths and weak points,
while PESTLE analysis focuses on the outside variables. Making use of both
approaches together creates a thorough assessment for the industrial transformation
and offers valuable insights into the enterprise and its standing against the rivals. This
leads to another pertinent question when should SWOT analysis as well as PESTLE
analysis be utilized? SWOT analysis is utilized to satisfy efficiency requirements
preparing for a considerable business transformation to enhance business processes,
whereas PESTLE analysis is utilized to understand exactly how the enterprises
choose the suit of travel within or toward industrial transformation affecting aspects
of the outside world. Development in the industrial sectors is moving at a lightning
speed, and NPD and NPI are transforming at an extraordinary rate. Falling behind
competitors is a setback for the production venture around the world. SWOT and
PESTLE are heavyweight strategic tools that are vital for getting insights, taking
advantage of opportunities and reducing the threats of industrial transition. A thor-
ough study will bring big benefits, and the SMEs and OEMs utilize both the tools
wherever required for the successful industrial transformation journey.
BUSINESS USE CASE

Manufacturing enterprise leaders are faced with a frustrating number of choices for
process automation, process improvement and customer interaction. Bound to com-
bine many self-controls to best offer the customer and realize meaningful organiza-
tion impacts. Industrial transformation is a journey; to get to the destination, the
correct roadmap is essential to drive the transformation in a reliable method. The
roadmap starts with an evaluation of the existing culture, skills, structure, capac-
ity, process, jobs, technology, work centers, equipment and innovation maturation
and moves on to an interpretation of a future vision, goal and implementation plan.
Success relies on how the process transformation is implemented and ensuring that
people are ready to accept it and move forward with the trends in technological
advancement. Consider a business use case of inventory management in a process
industry. Where one of the most difficult and crucial duties that the connected inven-
tory planning plays in inventory monitoring is that of promoting the balancing of
inward supply and outward supply.
Business Challenge
Inventory management is one of the main points the manufacturing enterprises
should consider as an obstacle for building their business. Inventory management is
vital to operate an effective service, with the consumer’s complete satisfaction and
reliant shipment times as well as supply control. A key function of inventory monitor-
ing is having a reliable snapshot of the existing supply amounts. The inventory moni-
tor updates stock counts using a regular stock analysis and utilizes effective supply
systems to maintain real-time records of stock levels, ensuring that the enterprise
supply chain team comprehends its supply placement is perpetually precise. To prop-
erly manage the flows in the supply chain, firms have to manage upstream supplier
exchanges and downstream customer needs. Manufacturing enterprises dealt with
smart manufacturing need to hold an inventory of basic materials, extra components
and finished goods in the future smart connected environment.
Precondition
Traditional inventory management has actually been the primary trend in the inven-
tory monitoring space, supplying much better projections showing past sales fads,
real-time monitoring and integration with other modern technologies. Traditional
stock monitoring helped in decreasing the time invested on manual supply takes as
well as uses more accurate data. As technology for services is swiftly enhancing, the
use of the future smart connected inventory management will work along with AI,
ML, IIoT, cobots and ESG along with human intelligence and will become the norm.
Approach
Data are collected dynamically at each of the process steps. Innovation that makes it
possible for future smart inventory management systems comprised of MES, industrial
control system (ICS), MRP, radio-frequency identification (RFID) tag, RFID antenna,
RFID reader, along with Industry 4.0 and Industry 5.0 technological innovations.
Steps followed are as follows:
• Re-engineering the processes

• Keep track of the vehicle dynamically
• Process traces of the raw material
• Use through opening load cells or pancake load cells for weighing
• RFID along with the industrial technological innovation for tracking.
The MES is integrated with vehicle tracking system (VTS) that is responsible for truck
movement from the entrance to the exit. Integrate the information flow from MES
Customer Order Supply and Process Design Process Service

Business Process / Requirement Inventory
Supplier to Customer Raw Materials Warehouse Operation Quality Check Finished Good
Process flow and Component
Inventory Monitoring
Assess current Material Material Material

Movement and Consumption, Scrap, Weighing, AI Quality Assurance
State and Target preparation, assisted Visual and with Human
Level, GRN Weight of Material Handling by Cobot ESG
X-ray Inspection, Intelligence followed
Rework by Shipping
Production Planning, Manufacturing Process Control Information and

Integration
Scheduling and Operation Execution System and Communication
of Process Control (MRP and (MES) Distributed Technology
MRP-II) Manufacturing System
FIGURE 7.4 Process transformation-mapped framework.

116 Industry 5.0
Manually entering time and

Receive Raw material details of Raw Material Raw material and Chemical
Enter Details in MRP System
in warehouse Stored in Storage Area in Mixing Area
ERP system
Enter details in MES and Quality Check Building Process Area Manually Weighing the Mix
Finished Good
ERP System
Enter Exit time of Vehicle in Receive Finished Good

Upload to Warehouse
ERP System in warehouse
FIGURE 7.5 Before—traditional inventory monitoring system.
along with MRP and VTS. The system captures actual net weighing of all the raw
material receipts before generating goods receipt note (GRN). GRN generation and
inventory update are mistake-proofed by automating the process. MES helps the shop
floor personnel with the display of production plan, recipe selection and the number
of final products to be produced, while MRP ensures the issue of raw material as per
the plan issued by planning department. MES terminals have RFID reader installed
at the packer’s stacker. The load cells installed help to capture weight of each batch
tagged with storage location. MES will update MRP with the inventory and production
information on a periodic basis. MES verifies material with the current running recipe
and alerts the user if wrong material is inputted; it ensures process validation and per-
formance of the smart connected inventory system. The connected digital environment
will track the actual collective weight of all the input material fed as well as establish
traceability of the material till the final finished good through suppliers.
The future smart inventory records the dynamic supply in real net weight; besides,
ranges of resources are tape-recorded and updated in actual time, and also, the signals
are pushed on to a mobile or over an e-mail to the supervisors, preparation employees
and storage personnel. KPIs and reports are given on a dynamic IIoT control board as
well as IIoT platform for the whole enterprise with live drill down to the plant level.
The future upgraded system connects every possession within a manufacturing orga-
nization; this gives exposure to the basic raw material, finished goods, job in progress
in addition to their location and problem. Making use of the framework and the con-
nected technology in real time, the future smart stock surveillance system utilized
interconnected intelligent systems, AI and cobot along with human touch making
handling supply smooth. It produces a smarter and aggressive inventory system can
be quickly shared and accessed in real time by anyone, anywhere. In turn, removing
hands-on processes, utilizing human intelligence and achieving conformity and get-
ting rid of wastes—waiting time, raw material, manual movement of raw materials,
storing and stocking of raw materials, waiting between process steps.
Result
The future smart IIoT-based inventory monitoring and property tracking sys-
tem use consistent presence right into the stock by offering real-time details
brought by RFID tags. It assists to track the accurate location of resources, work
in progress and finished products. As an outcome, manufacturers can stabilize
RFID reader Capture and

RFID reader Capture and update as well VTS capture ICS involved in Raw
Receive Raw material in
update details in MRP entering time and details of material and Chemical
warehouse
System Raw Material Stored in Mixing Area
Storage Area in ERP system
Automatic capture of details Human Intelligence with AI Automated Weighing the

Finished Good Building Process Area
in MES and ERP System in Quality Check Mix
AI VTS capture Exit time of

Value Addition:
Cobot helps in Upload to Receive Finished Good Reduction of waiting
Vehicle and update in ERP
Warehouse in warehouse time, Movement of raw
System
materials by Cobot,
Storing and stocking of
raw materials updating
by AI, Zero waste, ESG
compliance ecosystem .
FIGURE 7.6 After—the future smart connected inventory monitoring environment.
the amount of on-hand inventory, boost the usage of equipment, reduce lead time
and, therefore, stay clear of concealed costs bound to the much less reliable hand-
operated techniques with zero wastage of raw material forming an ESG compli-
ance ecosystem.
WORKPLACE OF THE FUTURE

Technical development helped in the form of employee help systems originated from
industrial transformation and can make jobs in the manufacturing sector available
for physically challenged persons with the evolution of assistive technology by pro-
ducing new better systems and changing the workplace of the future. An additional
need is the development of discovering systems that enable university graduates to
upskill themselves in the transformational modern technologies closing the missing
out on gap at a regular time as that of the evolving work environment. Industrial
improvement is transforming staff members interact with each other and with the
next-generation tools.
AI have actually progressed to end up being the foundation of several smart con-
nected products and services of the industrial sectors. AI together with Cobots,
AI with generative design, AI with self-assistance etc. offers help to physically
challenged individuals in work potential as well the opportunity to take part in
upgraded industries.
(Soni et al., 2020)
Most of the manufacturing enterprises beginning to stay on the top of progress-

ing health and safety regulations that can change instantaneously. Without d igital
devices, employees are not outfitted to work effectively in the manufacturing facili-
ties of the future. As newer technology disruptions alter the technology landscape,
they make way for less costly for open resource innovations that are readily available
to SMEs looking to reduce expenses and enhance business transformation processes.
118 Industry 5.0
SUMMARY
The ultimate goal of Industry 4.0 to Industry 5.0 transformation is to enhance
engineering and manufacturing processes. With that in mind, it is wise to focus
on end-to-end constant process improvement, collaboration and sustainable eco-
system. Embracing the organizational change is the secret to effective transition.
Industry 3.0 to 4.0 is transforming the means of the suppliers operated, merging the
physical and digital environment with each other. Similarly, Industry 4.0 to 5.0 will
certainly produce higher value jobs, as humans are repossessing jobs that require
creative thinking for improving effectiveness, planning approaches for a combina-
tion of robots and cobots. It is everything about utilizing the power of electronics
along with renewable energy transformation throughout end-to-end process within
the enterprise, taking on the technical development from engineering via manu-
facturing. Industry 5.0 takes manufacturing organizations through the brand-new
remarkable joint world of robotics and humans through Internet of Things (IoT)/
IIoT and various other modern technological innovations to obtain the work made
with accuracy and precision with minimum wastefulness and almost no mistakes.
SMEs, part suppliers, OEMs will certainly have the ability to appreciate and enjoy-
ing benefits of these technologies with a preliminary financial investment as noth-
ing comes as a complement.
When computers were presented in Industry 3.0, it was turbulent, thanks to
the addition of an entirely brand-new innovation. Now, and also into the future
as Industry 4.0 unfolds, computer systems are linked and also connect with one
another to ultimately make decisions without human involvement. A mix of cyber-
physical systems, IoT and the Internet of Solutions make Industry 4.0 possible and
the smart manufacturing facility a truth. As a result of the assistance of smart
equipment’s that maintain getting smarter as they get access to more information,
manufacturing facilities will end up being more effective, efficient and less waste-
ful. Eventually, it is the network of the manufacturers who are digitally connected
with one another, develop and share information across the enterprise that results
in real power of Industry 4.0. If the current transformation highlights the change
of manufacturing facilities into IoT-enabled smart facilities that use cognitive
computer, adjoining through cloud computing, Industry 5.0 prepares to focus on
the return of human hands along with creative minds into the industrial structure.
Industry 4.0 is about the interconnectedness of manufacturers with systems for
optimal performance. Industry 5.0 takes such effectiveness, efficiency and human
intelligence much better by developing the interaction in between humans with the
Industry 4.0 technologies.
Imagine a technology that can provide real-time or instant accessibility to
details, along with the computer system power just by idea alone. According to
new research study by the United States neuroscientists and nanorobotics scien-
tists, a matrix-style human mind to cloud user interface, that acquaint as Internet
of Thoughts network, can be a possibility in the future, i.e., the human mind to
cloud interface. By simply utilizing a mix of AI and nanotechnology, research-
ers stated that human beings will completely have the ability to connect their
minds to shadow local area network to gather details from the Web in real time.
Currently, experiencing Industry 4.0 and Industry 5.0, Internet of Thoughts makes
sure to bring ourselves on the Internet where it would certainly have the ability to
take Industry 6.0 revolution right into our real life. Are you being empowered by
the capacity to digitally collaborate with brand-new modern technologies besides
the idea of accomplishing new elevations of engineering and manufacturing effec-
tivity that excites as well as motivates? If the response is indeed, then we think
alike and move ahead in the industrial transformation journey!
Index
Note: Italic page numbers refer to figures.
3D printing 36, 37, 43, 58, 59, 62, 78, 79, 90, 97, automated 5, 12, 14, 16–18, 29–31, 33, 40, 54,
98, 100, 101, 104, 110, 113 62, 67, 68, 70, 79, 80, 83, 98, 100, 101,
4D printing 39, 43, 44, 62, 79, 113 110, 117
4G 34 automation 1, 7, 8, 11–33, 40, 41, 44, 45, 47, 49,
5G 34, 76 51, 52, 54–56, 60, 62–64, 67–70,
72, 74–76, 78–84, 89, 90, 93, 95, 96,
actuators 14, 30, 31, 35, 55, 56, 79, 90 98–100, 102, 104, 105, 107, 108, 110,
adapt 2–4, 6, 28, 43, 60, 70, 75, 81, 97 113, 114
ADAS 70 automobile 11, 27, 28, 47, 49, 52, 56, 59–64, 68,
additive manufacturing 33; see also 3D Printing 70, 75, 83, 101
adoption 1, 8, 22, 25, 30, 35, 43, 59, 61, 62, 72, 77, automotive 27, 28, 36, 38, 47–65, 69, 70, 75
102, 109 aviation 27, 70, 99–101
advanced product quality planning 48
advancement 1, 3, 5–7, 11, 16, 17, 25–28, 30–33, baseline 51, 112
38, 39, 47, 54, 56, 58, 62–64, 67, 68, battery 47, 64, 76, 88–90, 92, 99
70–74, 76, 77, 81, 82, 85, 88, 93, 95, benefits 8, 16, 19, 20, 26, 27, 29, 30, 32, 33, 35, 38,
102, 104, 105, 107, 108, 113, 114 39, 44, 50, 51, 61, 68, 70, 72, 78, 83, 84,
advance process control 68 97, 98, 100, 101, 103, 110, 114, 118
aerospace 11, 36, 38, 57, 69, 70, 83 bionics 39
AGV 31, 62 Bisphenol A 94
AI 11, 16–19, 38–43, 58, 62, 63, 69, 70, 76, BMW 59
80–84, 89–93, 95, 97, 100, 103, 104, BOM 2, 73
110, 112, 113, 115–118 BPA 14, 15
aircraft 28, 99, 100 budget 18, 19, 91, 97
alloys 27, 56, 65, 96 business use case 114
Alphabet Inc. 4
aluminum 56, 65, 94, 97 CAD 13, 19, 24, 29, 36, 43, 53, 54, 58, 70, 73, 101
Amazon 37 CAE 11, 13, 97
AMS2750 57 CAM 13, 24, 29
analysis 5, 11, 13, 38, 44, 48, 50, 63, 70, 74–76, CAPA 74, 78, 80
78, 86, 93, 94, 97, 98, 102, 111–114 capabilities 14, 18–20, 23, 30, 34, 42, 44, 47, 57,
analytics 7, 18, 20, 23, 32, 33, 35–39, 42, 45, 59, 60, 67, 70, 72, 74, 75, 80, 92, 95,
52, 58, 82, 85, 90–92, 96, 98, 99, 97, 102, 110
104, 110 capitalize 3, 28
Ansys 70 carcinogen 33
antenna 43, 78, 115 car 55, 59, 63, 70
apparel 26, 90 CAx 13, 53
Apple 2, 9 CFD 96, 97, 103
approach 1, 5, 7, 11, 14, 19, 43, 44, 49–51, 53, 55, CFT 12, 19, 33, 51, 53, 59, 77, 84, 85, 110–112
57, 63, 65, 70, 73, 75, 86, 88, 94, 95, challenges 1, 3, 7, 19, 21, 22, 39–41, 44, 48,
97, 101, 102, 107, 108, 111, 112, 114, 51, 53, 55, 56, 60, 61, 67, 70, 73, 76,
115, 118 80–83, 90, 94, 97–100, 103, 105,
approval 14, 48, 54, 85 107–109, 114
artificial intelligence see AI change 1–4, 6, 7, 9, 11, 13, 14, 16, 19–21, 23,
ASPICE 60 25, 26, 28, 37, 40, 44, 45, 51, 52, 59,
assembly 7, 15, 27, 29, 32, 38, 41, 54, 62, 67, 69, 61–64, 67, 68, 70, 75, 83, 87–89, 99,
71, 72, 74, 75, 78, 82, 86 101, 102, 104, 108, 109, 111–113,
augmented reality 33, 37, 42, 59, 77, 80, 89, 110 117, 118
121
122 Index
Chatbot 42, 43, 45 cost-effective 28, 39, 67, 71, 76, 81, 98
chemical 27, 78, 79, 103, 116, 117 COVID-19 6, 38, 70, 84, 87, 89, 95, 100, 102, 107,
chips 35, 70, 75, 77 108, 111
CIM 1, 11, 13, 28, 29 CQI-9 57
C-level executives 4, 5 cross functional team see CFT
CLFR 91, 105 critical to quality 49
client 1, 3, 5, 9, 13, 18, 20, 22, 42–45, 48–50, culture 3, 4, 8, 20, 25, 45, 50, 64, 84, 114
59–61, 72, 82, 85, 100, 102, 105, 107, customer 1, 2, 6, 7, 12–14, 16, 17, 20, 23, 25, 28,
110, 111 37, 38, 43–45, 47, 48, 51–53, 56, 60,
closed-loop 30, 55, 71, 74 61, 64, 68, 71, 75–77, 82, 87–90, 96,
cloud 15, 17, 33, 35, 54, 61, 81, 84, 87, 89, 98, 100, 103, 107, 108, 113–115
110, 118 cyber 18, 32, 33, 112, 113, 118
CNC machines 29, 31, 40, 58, 113
coal 26, 27 data 1, 6–8, 11–17, 19, 20, 22, 29, 32–40, 42,
cobot 41, 58, 62, 80, 81, 115–117 44–46, 51–56, 58, 60–63, 72–74, 77,
cognitive 16, 18, 110, 118 79–81, 83–85, 87, 89–92, 94, 96–99,
collaboration 23, 40, 86, 118 101, 102, 104, 109, 110, 112, 115
collaborative 7, 11, 39–41, 76, 77, 86, 94, 110, 119 decarbonization 88, 91
communication 6, 8, 11, 13, 14, 29, 59, 61–63, 69, decentralization 45, 68, 88, 91
76, 79, 83, 89, 94, 104, 105, 108, 110, decision 9, 14, 17, 19, 29, 31, 32, 38, 41, 42, 49–51,
112, 115 59, 62, 71, 73, 81, 85, 89, 91, 96,
competitive 1–3, 6–9, 13, 20, 28, 41, 45, 60, 102–104, 108, 118
61, 64, 80, 82, 84, 88, 93, 97, 100, decrease 12, 16, 30, 54, 56, 59, 64, 70, 73, 79, 84,
104, 108 85, 89, 93, 96, 98, 100
component 11, 13, 14, 30, 34–36, 38, 39, 42, deep learning 42, 70
47–53, 55, 56, 58–62, 64, 67–75, 78, defect 49, 75, 78, 83, 96
80–82, 84, 85, 89, 93, 94, 97, 103, 104, defect mapping tool 80
111, 113, 115 defense 11, 83
computational fluid dynamics see CFD demand 3, 6–8, 13, 14, 16–19, 21, 23, 38, 39, 42,
computer aided design see CAD 44, 48, 50, 51, 54, 56, 60, 62, 64, 67,
computer aided engineering see CAE 68, 71, 72, 76, 78, 83–85, 89–95, 98,
computer aided manufacturing see CAM 104, 107, 109, 110, 113
computer integrated manufacturing see CIM density 90, 103
computer numerical control see CNC dental 94, 97, 98
computing 18, 33, 38, 53, 54, 63, 65, 87, 118 dependability 30, 48, 68, 79, 100
concept 1, 11, 13, 35, 44, 48–50, 53, 58, 61, 62, design 1, 2, 7–9, 11–14, 16, 17, 19, 23, 25, 28, 29,
68, 71, 80, 91, 93, 108, 109, 111 37–39, 43, 44, 47–49, 51–54, 58–60,
configuration 13, 53, 54 62, 64, 65, 67, 69–74, 77, 78, 82–87,
conformity 15, 59–62, 74, 87, 93, 98, 116 93, 94, 96, 101–103, 105, 110, 115, 117
connected 3, 6, 14, 17, 20, 22, 32, 33, 35–37, 52, designer 12, 13, 19, 37, 38, 43, 51, 53, 59, 69, 70,
55, 57, 60, 63, 64, 67, 68, 73, 76, 78, 73, 74, 76, 77, 101–103
80, 84, 85, 87, 89, 92, 101, 102, 107, design of experiment 94, 95
109, 110, 114–118 development 1, 4, 6–8, 11–15, 18, 19, 22, 25–29,
connectivity 32, 34, 60, 84, 92, 102 31, 35–40, 42–45, 47–54, 56, 58–65,
consumer 6, 13, 17, 21–23, 28, 30, 36, 38, 40, 42, 67, 69–78, 81, 86, 87, 96, 97, 100, 103,
48, 50–52, 59–61, 63, 64, 67, 68, 71, 105, 108–110, 112–114, 117, 118
81, 82, 87, 88, 91, 95, 98, 99, 104, 113 device 2, 7, 8, 15, 16, 28, 29, 31, 34, 35, 37, 38, 40,
consumption 57, 84, 88, 89, 92, 95, 102, 115 42, 44, 47, 50, 55, 57, 62–64, 67–70,
contamination 69, 94, 114 72–79, 81–85, 87, 90, 91, 93–95, 97,
conventional 6, 11, 17, 29, 34, 36, 37, 42, 62, 100, 104, 110, 117
78, 103 dexterity 32, 41, 97
corrective action preventive action see CAPA DFM 37, 71
cosmonaut 43 DFMEA 70, 71, 74
cost 12, 13, 17, 20, 22, 35, 40–42, 44, 48, 49, DFR 71, 72
54, 56, 58, 60, 67–69, 74–76, 78, 79, diagnostics 57, 81
81–83, 87–89, 93, 94, 96, 97, 99–101, digitalization 1, 5, 19, 54, 63, 64, 69
103, 104, 107, 110, 112, 113, 117 digital process automation 17, 24
Index 123
digital transformation 12, 16, 17, 19, 20, 25, 33, equipment 27, 30, 38, 42, 47, 49, 53, 55–57, 62,
35, 36, 42, 44, 47, 52, 68, 69, 107 65, 67, 69, 71, 72, 75, 77, 83, 85, 87, 94,
digital twin 8, 33, 39, 40, 42, 74, 89, 100, 113 98–101, 108, 110, 113, 114, 117, 118
digitization 15, 23, 35, 60, 61, 97, 99, 107 ERP 1, 5, 9, 14, 16, 19, 29, 31, 37, 53, 56, 73, 80,
distribution control System 30, 31, 55, 56, 80, 104 85, 109, 116, 117
DMR 15 errors 13, 16, 19, 32, 48, 49, 100
downstream 51, 115 ESD 78, 79
downtime 28, 31, 35, 40, 42, 64, 81, 85, 90, 98, essential 1, 2, 4, 5, 11, 12, 15–17, 19, 30, 31,
100, 101, 103, 112 34, 38, 47, 50, 52, 53, 58, 61, 64, 71,
drones 36, 93 74–76, 78, 79, 82–85, 93, 94, 96, 101,
drug 42, 43, 94 103, 107, 108, 110, 114
durable 44, 110, 113 evaluation 19, 35, 38, 41, 42, 70, 71, 73, 77, 90,
dynamic 14, 17, 33, 67, 68, 77, 78, 80, 89, 92, 96, 93, 94, 98, 103, 108, 111–114
99, 100, 103, 110, 115, 116 evolution 8, 41, 52, 86, 107, 117
examples 3, 18, 34, 37, 58, 93
EaaS 89 excellence 17, 38, 53, 71
earnings 12, 92, 109, 113 executives 4, 5, 8, 24, 45, 50, 102, 105, 107,
ECAD 73, 80 109, 110
eco-driven 105 existing 4, 5, 8, 15, 17, 21, 32, 44, 45, 52, 56, 60,
eco-friendly 97, 99, 101, 104 62, 80, 85, 90, 91, 97, 99, 107–110,
economic 1, 6, 18, 39, 45, 46, 62, 70, 75, 84, 86, 113, 114
89, 108, 113 exoskeleton 22, 63
economy 20, 22, 25, 26, 34, 39, 40, 42, 52, 63, 67, expectations 6, 17, 20, 47, 48, 52, 61, 79, 96,
76, 82, 83, 88, 95, 99, 105, 111, 113 107, 111
effectiveness 1, 2, 8, 9, 11, 12, 14, 15, 19, 20, 28, expenses 1, 7, 11, 18, 19, 28, 30, 43, 44, 49, 52, 62,
31, 33, 35, 38, 39, 42, 44, 45, 48, 50, 64, 70, 72, 73, 76, 78, 79, 82, 84, 85,
57, 59, 62, 65, 68, 69, 75, 83, 84, 88, 87–89, 91, 98, 102, 117
90, 94, 100–104, 107, 110, 112, 118 extrusion 93–96
effectivity 18, 55, 76, 79, 81, 85, 102, 110
efficiency 3, 6, 11, 17, 18, 21, 26, 28, 31–33, fabric 45, 47
35, 37–39, 48, 49, 58, 68, 74–76, 87, fabrication 40, 58, 68, 69, 71, 74, 95
90–93, 95, 97–100, 103, 104, 108, 110, factor 11, 13, 18, 35, 37, 44, 47, 70, 71, 78, 81,
114, 118 82, 85, 89, 91, 93, 102, 103, 108, 110,
electromagnetic 76, 82 111, 113
electronic design automation 69, 70, 74 factory 1, 26, 33, 35, 36, 40, 46, 48, 50, 64,
electronic manufacturing service 59, 67–74, 76, 67–69, 76, 81, 83, 88, 94, 110
77, 80–82 fad 6, 47, 60, 64, 87, 98, 102, 113, 115
electrostatic 78, 79 FANUC 40
emerging 1, 9, 22, 32, 41, 43, 61, 68, 89, 100, 113 farming 26, 33, 36
emission 60, 64, 76, 77, 88, 104 feasible 15, 19, 38, 49, 50, 52, 60, 70, 71, 92,
energy 5, 23, 27–29, 33, 36, 38, 39, 42, 43, 57, 64, 93, 101
65, 69, 75, 76, 83, 84, 87–96, 98, 101, Fiat 50
102, 104, 105, 110, 113, 118 financial 3, 11, 12, 15, 19, 28, 50, 61, 71, 75, 77,
Energy-as-a-Service see EaaS 81, 82, 84, 89, 91, 93, 98, 105, 107, 118
engineering 9, 11–14, 18, 43, 45, 46, 48, 50, 51, fixtures 78, 81
53, 62, 65, 71, 73, 76, 85, 91, 97, 110, flow 9, 14, 27, 49–51, 61, 63, 77, 92, 96, 97, 103,
118, 119 110, 115
enhancement 2, 32, 37, 49–51, 63, 90, 94, 98, fluctuations 49, 76
99, 102 fluid 30, 77, 96, 97, 103
environment 7, 9, 14, 19, 22, 23, 28, 33, 34, Food and Drug Administration 15, 43, 93
37–40, 45, 53, 56, 57, 59, 62, 63, 69, Forbes 8
73, 74, 80, 84, 87, 88, 91–93, 98, 99, forecast 38, 39, 62, 76, 85, 92, 93, 97, 103, 107,
105, 108, 115–118 110, 112
environmental, social and corporate governance foundation 54, 63, 75, 82, 100, 104, 111, 117
95, 112, 113, 115, 117 framework 1, 3, 22, 33, 47–50, 59, 60, 78, 90, 99,
environment-friendly 39, 44, 57, 64, 101 111, 113, 115, 116
environment management system 98, 99 fundamental 8, 21, 26, 35, 85, 95, 102
124 Index
furnace 57, 93 Industry 4.0 1, 6, 8, 11, 14, 16, 18, 19, 21, 22,
future 2, 4, 5, 8, 9, 11, 20, 22, 23, 32, 39, 41–43, 32–35, 38–40, 43–46, 50, 52, 54,
45–48, 51, 58, 61, 64, 67, 70, 71, 82, 59, 61, 63, 64, 67, 68, 71, 76, 80, 81,
85, 87, 88, 90, 92, 98, 99, 105, 107, 83–90, 92, 95, 97–100, 102, 104, 105,
108, 110, 111, 113–118 107, 108, 110, 115, 118, 119
Industry 5.0 8, 18, 25, 39, 40, 43, 44, 61, 63, 64,
gadget 30, 35, 36, 40, 69, 76, 79, 89, 103 76, 80, 81, 83–85, 89, 95, 99, 100, 102,
gap 5, 7, 19, 61, 98, 109, 111, 112, 117 104, 105, 107, 108, 110, 115, 118, 119
gas 58, 87, 99, 101–103 Industry 6.0 119
generative design 39, 43, 103, 117 innovation 1, 2, 4–8, 11, 14, 16–20, 22, 23, 25–29,
globalization 3, 12, 87, 108 33, 35, 37–43, 45, 47, 48, 50–53, 55,
goal 4–6, 19, 50–52, 61, 70, 72, 84, 89, 109, 111, 58–65, 67–70, 72, 73, 75, 76, 79, 81–83,
112, 114, 118 85, 86, 88, 89, 91, 95, 99, 100, 102, 104,
goods receipt note 115, 116 105, 107–111, 113–115, 117, 118
Google 4, 42 insights 4, 27, 37, 42, 77, 81, 82, 87, 90, 91, 99,
governing 93, 95, 98, 101, 104 100, 112, 114
government 113, 114 inspection 15, 41, 64, 80, 115
Grid 26, 88, 89, 92, 104, 105 integrated 4, 12, 13, 28, 33, 50, 63, 67–70, 74, 76,
ground power unit 99, 101 77, 81, 97, 110, 115
ground support equipment 99–101 intelligent-process-automation see IPA
guarantee 6, 17, 22, 38, 55, 57, 60, 61, 71, 90, 91, Internet 1, 8, 14, 23, 28, 29, 32–36, 44–46, 69, 89,
97, 99, 100, 102, 103, 110 102, 110, 118, 119
guidebook 37, 65 Internet of Things 33–36, 63, 79, 89, 91, 92, 96,
guidelines 56, 60, 83 101, 113, 118
Internet of Thoughts 118, 119
hand-operated 55, 56, 63, 81, 117 inventory 13, 16, 36, 60, 80, 110, 114–117
hardware 2, 28, 29, 32, 35, 55, 62, 90 investment 3, 5, 6, 8, 12, 15, 16, 19, 21, 38, 45, 50,
harness 70, 105, 107 59–61, 68, 76, 81, 88, 91, 98, 103, 107,
harvesting 76, 82 109, 113, 118
healthcare 5, 36, 67, 70, 79, 99, 102, 108, 113, 117 IPA 17, 18, 23
heat treatment 55–58 IPC-1752 74
high-quality 11, 28, 47, 51, 52, 59, 63, 74, 95, 96 IPC-6011 74
hi-tech 67, 69, 75–77, 90 IPC-A600 74
HMI 30, 55, 56, 80 IPv6 35
hospital 33, 36 iron 26, 28
household 26, 27, 33, 87 ISO 41, 98, 101
human-machine-interaction see HMI iTunes 2
hybrid 75, 99
hydraulic 33, 57 jenny 26
hydroelectric 27, 88, 104 jetting 79
hydrogen 58, 88 jidoka 49
jigs 78
IATF 48, 59 journey 6, 13, 16, 19, 23, 25, 33, 50, 52, 54, 61, 63,
ICS 115, 117 64, 90, 99, 105, 108–110, 114, 119
ICT 30, 108, 110 just-in-time 28, 30, 49
IDOV 49
IEC 104 kaizen 49
implementation 5, 8, 16, 18, 20, 28, 35, 39, 50, 54, knowledge 20, 23, 42, 95, 110
65, 81, 89, 98, 114 KPI 4, 81, 109, 116
Industrial Internet of Things 1, 14, 17, 19, 23,
32–36, 38, 50, 52, 55, 57, 58, 60, 63, labor 15, 31, 62, 64, 69, 70, 75, 77, 79, 91, 96, 102,
69, 71, 80, 84, 85, 89, 96, 102–105, 110, 113
110, 113, 115, 116, 118 ladders 99, 100
Industry 1.0 11, 26, 28, 34 landscape 1, 8, 18, 21, 27, 31, 45, 60, 80, 89, 117
Industry 2.0 11, 27, 28, 86 leaders 2, 3, 7, 8, 17, 20, 25, 45, 47, 53, 88,
Industry 3.0 11, 25, 28, 29, 32, 34, 39, 55, 61, 63, 104, 114
64, 84, 88, 108–110, 118 lean 28, 41, 45, 49, 50, 63, 65, 86, 105, 112
Index 125
learning 8, 17, 18, 32, 38, 42, 43, 52, 62, 89, 110 natural language processing see NLP
locomotive 26 networks 23, 42, 92, 103
logistics 16, 46, 50, 62, 64, 80, 85, 87, 100 neural network 14, 42
neuroscientists 118
M2M 35, 58, 63, 69, 80, 112 NLP 15, 18, 42
machine 2, 14, 19, 22, 26–31, 33, 34, 37, 39–42, non renewable 88, 104
44, 48–50, 55, 56, 64, 80, 85, 88, 93, non value added 50, 52, 96
97, 98, 107, 109, 113 NPD 11, 12, 14, 29, 38, 43, 44, 48, 49, 51, 53, 54,
machine learning 8, 17, 18, 32, 38, 42, 43, 52, 60, 59, 67, 71, 73, 74, 77, 93, 97, 100, 102,
62, 89, 110 103, 110, 113, 114
machine-to-machine see M2M NPI 11, 29, 51, 53, 54, 59, 67, 71, 73, 74, 77, 110,
machining 40, 56, 97, 102 113, 114
maintenance 30, 31, 42, 49, 56–58, 67, 81, 85, 91, nuclear 28, 29, 101
92, 98–101, 104, 105
manual 5, 15, 16, 19, 22, 31, 56, 64, 72, 78, 80, objective 1–3, 5, 6, 11, 12, 20, 21, 23, 30, 43, 52,
103, 104, 107, 109, 110, 115, 116 61, 68, 76, 84, 89, 96, 107, 111, 112
manufacturer 1, 7, 9, 11–15, 17–19, 22, 23, 25–28, obstacle 3, 16, 18, 56, 59, 71, 89, 97, 102, 109, 114
30–34, 36–42, 44, 45, 47, 48, 50–52, OCR 18, 79
55, 58, 60–64, 67–72, 75–77, 79, 82–88, ODM 67, 70–72, 74, 76, 77, 79, 81, 82
93, 98, 99, 101–105, 107–110, 116, 118 OEE 38, 65, 104
manufacturing 1–3, 5–9, 11–23, 25–64, 67–91, OEM 31, 48, 51–53, 55, 58–63, 67–70, 72, 81, 82,
94–99, 101–105, 107–110, 114–119 87, 95, 97–101, 104, 105, 108, 109, 113,
mapping 5, 9, 50, 75, 78 114, 118
market 3–7, 11–14, 19, 21, 23, 28, 36, 40, 43, online 22, 37, 42, 57, 96
47–49, 52, 56, 59–61, 63, 67–70, 72, operation 1–3, 7, 8, 12, 13, 15, 20–22, 27, 30–33,
73, 82, 87, 89–91, 95, 98, 101, 102, 36, 38, 42, 44, 45, 51, 52, 55, 57, 63,
107, 109, 111–113 68, 69, 76, 77, 79, 81, 82, 84, 89–91,
marketplace 2, 21, 28, 48, 67, 80, 97 93, 95, 96, 98, 99, 101, 103, 105, 107,
material 2, 7, 17–19, 21, 23, 25, 27, 28, 40, 41, 43, 108, 110, 112, 115
44, 53, 55–57, 62–65, 67, 68, 73, 74, operational 3, 19, 31, 35, 38, 49, 75, 81, 83, 87, 91,
77–80, 84, 85, 87, 94–98, 102, 109, 94, 96, 98, 100–103, 107, 112
110, 113, 115–117 operators 8, 55, 59, 83, 92, 104, 110
maturity 14, 20, 54, 109 optimization 33, 44, 52, 62, 77, 89, 96–98, 103,
MDMs 93, 94 104, 110
mechanical 7, 25, 26, 47, 56, 73, 77, 78, 97
medical 5, 11, 15, 42, 67, 69, 83, 93, 94, 97 PAC 56, 80
MES 1, 14, 16, 19, 24, 29, 31, 37, 53, 55, 56, 73, pandemic 6, 38, 70, 84, 87, 95, 100, 102, 107, 108,
75, 80, 83, 85, 98, 109, 115–117 111, 113
methods 2, 3, 6, 7, 11, 17, 19, 21, 23, 33, 37, 38, paradigm 1, 26, 34, 72, 107
43, 44, 49, 51, 52, 63, 71, 78, 79, 82, parts 12, 14, 27, 30, 43, 47, 50, 56, 58, 59, 62, 64,
84, 91, 94, 96, 97, 101, 102, 104, 65, 67, 69, 71, 73–79, 83, 96, 97, 100
107–109, 111, 112, 114 PCB 69–75, 77–79, 81, 83–86
metrics 5, 21, 61, 110 PDM 13, 19, 53, 54, 80
microprocessors 28, 30, 64, 76 PEEK 79, 94
Microsoft Hololens 37 people 7–9, 12, 15, 18, 21, 32, 39, 40, 45, 50, 62,
mixed reality 37, 91 64, 80, 84, 111, 114
monitor 22, 30, 32, 34, 54–56, 68, 92, 96, 104, personalization 39, 42, 78, 80, 110
112, 114 PESTLE 113, 114
monitoring 3, 14, 17, 29, 31, 33, 55, 56, 59, 60, 62, PFMEA 70, 71, 74
73, 84, 85, 89, 90, 92, 95, 96, 98, 100, pharmaceutical 87, 93, 102
103, 104, 114–117 Philips 5
MRO 99, 100, 112 phones 34, 37, 70, 79
MRP 79, 80, 109, 115–117 pipeline 79, 93, 103
planning 1, 2, 5, 6, 9, 12, 16, 19, 20, 23, 28, 48,
nanorobotics 118 55, 60, 73, 85, 105, 109–116, 118
nanotechnology 44, 118 plant 27, 30, 38, 56, 57, 62, 88–92, 102–104, 116
NASA Jet Propulsion Lab 43 plastic 47, 79, 90, 93–98
126 Index
PLC 1, 29–31, 45, 54–57, 80, 104, 109, 110, 113 renewable 23, 28, 29, 39, 65, 87–89, 92, 93, 104,
PLM 1, 11, 13, 14, 16, 19, 23, 29, 53, 54, 71–74, 105, 110, 118
80, 109 requirements 1, 16, 22, 28, 30, 36, 39, 41, 51, 53,
political 113 57, 60, 63, 69, 74, 77, 79, 82, 85, 88,
polycarbonate 94, 96 101, 104, 107, 109, 110, 113–115
polymer 43, 79, 96, 97 research 1, 4, 7, 9, 24, 25, 30, 38, 42, 43, 48, 64,
polyvinyl chloride 87, 94 85, 86, 105, 109, 118
Porsche 58 resistance 3, 21, 69, 78
predictive 18, 33, 37, 38, 52, 57, 58, 80, 81, 85, 98, resources 1–3, 5, 11, 12, 17, 20, 22, 23, 25, 28, 49,
100, 104, 110, 112 50, 57, 60, 61, 65, 70, 72, 73, 75, 76,
process automation 11–15, 17–22, 28, 33, 69, 79, 84, 86–88, 90, 101, 109, 111, 113, 114,
80, 83, 89, 90, 95, 96, 99, 102, 105, 116, 117
107, 114 return of investment 16, 21, 61, 109, 112
process design 13, 38, 48, 51, 71, 101 return of value 16, 21, 109, 112
process optimization 44, 96, 98 revolution 6, 8, 25–29, 32, 33, 39, 47, 62, 77, 88,
process standardization 14, 22, 80, 112 104, 107, 119
process transformation 3, 5, 6, 11, 19–23, 51–53, RFID 16, 31, 34, 35, 115–117
60–62, 64, 75, 78, 82, 83, 89, 98, 100, risk priority number 70
104, 105, 114, 115 roadmap 111, 114
procurement 22, 78, 91, 102 robotic process automation see RPA
product design 1, 8, 11–14, 16, 17, 25, 28, 38, 39, robotics 1, 7, 8, 15, 19, 28, 30–33, 38–41, 52, 60,
43, 44, 49, 51, 53, 58, 59, 62, 64, 70, 63, 64, 67, 72, 74, 75, 79, 89, 104, 110,
71, 73, 74, 76, 77, 82, 83, 93–95, 97 118
product development 11–14, 22, 25, 36, 37, 47, robots 7–9, 11, 14, 15, 17, 22, 23, 29–32, 35, 36,
48, 51–54, 56, 58, 67, 72–74, 96, 39–42, 44, 45, 52, 62, 63, 72, 74–76,
108, 110 79, 81, 83, 86, 89, 109, 110, 113, 118
production 1, 2, 5, 7, 11, 13–17, 19–23, 25–32, RoHs 113
35–44, 48–53, 55, 56, 58–60, RPA 15, 16, 18, 23, 79, 80, 86, 89–91
62–64, 68–71, 74–77, 79–88, 92, 93,
95–97, 100–102, 104, 105, 107–110, safety 6, 22, 37–41, 48, 50, 56, 59, 61–63, 67, 70,
113–116 71, 75, 76, 82, 85, 91, 99–102, 104,
production part approval process 48, 57 108, 113, 117
product lifecycle management see PLM SCADA 1, 29–31, 54–57, 80, 90, 103, 104, 109,
PVC 94 110, 113
SCARA 32
quality 1, 2, 6, 11–16, 18, 19, 22, 28, 30–32, scheduling 5, 92, 115
38, 40–42, 44, 48–51, 53, 56, 57, 59, schematic 73, 77
60, 62–64, 67–72, 74, 75, 80–84, 93, scientists 26, 118
94, 96, 98, 99, 101, 103, 112, 113, scrap 61, 96, 98, 115
115–117 semiconductor 29, 67–69, 81
quantum computing 39 sensors 31, 34–36, 40, 42, 46, 55, 56, 58, 60, 64,
75, 76, 78, 79, 81, 92, 98, 100, 103,
radio-frequency see RFID 105, 110
raw material 25, 68, 80, 85, 94, 95, 110, 115–117 simulation 7, 11, 33, 38–40, 42, 73, 76, 77, 85, 96,
RCA 74 97, 102, 103
real-time 14, 21, 30, 31, 35, 38, 44, 50, 55, 63, Six Sigma 32, 49, 71
79–81, 83, 85, 90, 92, 93, 95, 98, 104, smart cities 76, 93
114–116, 118 smart grid 88, 89
recycle 73, 96, 113 smart machine 19, 22, 32, 44
redesign 2, 9 smart manufacturing 1, 11, 22, 32, 36, 44, 89,
reduction 15, 44, 47, 52, 64, 74, 98, 100, 110, 112, 108, 115, 118
113, 117 smart product 1, 7, 43, 62, 67, 76, 79, 113
reengineering 3, 115 SME 12, 13, 31, 43, 47, 48, 50–58, 60–64, 75,
regulation 73, 88, 110, 112, 113, 117 81, 85–87, 89–91, 94, 95, 97–101,
reliability 71, 74, 76, 83, 86, 94 103–105, 108, 109, 111–114, 117, 118
remote terminal unit 30, 56, 80 social 21, 40, 95, 113
Index 127
society 85, 101, 113 upgrade 1, 16, 19, 25, 56, 79, 98, 109
software 2, 12, 15, 28, 30–32, 34, 35, 41–43, 47, upkeep 37, 50, 81, 82, 85, 91, 94, 100, 102–104
52, 55, 60, 62–64, 70, 79, 80, 104 upstream 51, 115
solar 87–93, 101
solar photovoltaic 87, 88, 93, 105 vacuum 57, 95
soldering 69, 72 validation 38, 58, 62, 116
spacesuits 43 value 1, 2, 5, 7, 9, 16, 22, 25, 33, 38, 42, 45,
standard 22, 23, 29, 48, 49, 52, 54, 56, 57, 59, 50–52, 59, 61, 71, 84, 86, 91, 99, 100,
60, 63, 64, 68, 69, 74, 83, 87, 92, 101, 107–112, 117, 118
104, 111 value stream mapping 50
standardization 1, 14, 22, 47, 80, 108, 112 valve 31, 38, 87, 101–105
statistical process control 22, 32, 38, 48, 58, 68, vapor 91, 101
80, 94 variables 3, 18, 42, 48, 49, 63, 69, 70, 80, 93–96,
steam 26, 27, 91, 101 99, 103, 114
strategy(ies) 3, 9, 12, 17–21, 29, 43, 44, 48–50, 52, vehicle 27, 33, 35, 47, 55, 59, 62, 67, 76, 85, 90,
53, 61, 71, 80, 83, 87, 89, 90, 94, 101, 101, 115–117
104, 107, 109, 111–113 vehicle tracking system 115, 116, 117
streamlining 15, 20, 32, 50 virtual 15, 33, 38, 40, 74
strength 3, 15, 48, 52, 55, 56, 85, 91, 102, 111, virtual reality 8, 33, 37, 59, 89, 110
112, 114 visibility 61, 72, 81, 87, 92, 107
suppliers 2, 20, 22, 32, 38, 47, 48, 51, 52, 59, 60, visualization 38, 83, 90, 104
62, 67, 71, 73, 76, 78, 79, 81–84, 89,
94, 99, 100, 103–105, 115, 116, 118 wafers 68, 69
surface mount technology 72, 80 wastage 14, 95, 96, 110, 112, 117
surveillance 14, 30, 50, 57, 63, 81, 104, 116 waste 17, 18, 29, 30, 35, 39, 40, 44, 49, 50, 52, 64,
sustainability 3, 47, 54, 61, 65, 84, 86, 89, 90, 95, 79, 84, 85, 95–99, 101, 104, 110, 113,
102, 105 116, 117
sustainable 49, 65, 83, 84, 94, 105, 113, 114, 118 water 34, 43, 91, 103, 104
SWOT 111, 112, 114 Watt, James 26, 101
weaknesses 111, 112
technology 1, 3–9, 11, 12, 14–16, 18–23, 25, wearable 22, 33–37, 63, 70, 79
27–29, 31–33, 35, 37–40, 42, 43, 45, WEEE 85, 86, 113
48, 51–55, 57–59, 61–65, 67, 69, 72, welding 54, 102
76, 77, 79, 81, 84, 86, 87, 89–91, 93, wireless 32, 60, 85, 103
97, 99, 100, 102, 105, 107–118 workflows 13–15, 17–19, 73, 91
temperature 29, 56, 57, 80, 92, 93, 95, 96, 100, workplace 28, 89, 117
103, 104 world class manufacturing 50
Tokyo Olympics 8
tolerances 72, 75, 94 x-ray 115
touchless manufacturing 19, 70, 112
Toyota Production System 8, 49 yield 19, 38, 59, 68, 71, 75, 80, 82
traceability 48, 74, 116
zero 39, 50, 64, 69, 88, 110, 117
Universal 41, 68, 81 zero-defect 97
university 117 zero-waste 40
upgradation 78, 107 Zigbee 34
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Industry 5.

and by CRC Press

© 2022 Uthayan Elangovan

CRC Press is an imprint of Taylor & Francis Group, LLC

Library of Congress Cataloging‑in‑Publication Data

ISBN: 978-1-032-04127-8 (hbk)

To my parents, Elangovan Rajakani and Kanmani

Chapter 1 Industrial Transformation......................................................................1

Chapter 2 Engineering and Manufacturing Transformation............................... 11

Chapter 3 Technological Innovations of Industrial Revolution 3.0 to 5.0............25

Programmable Logic Controller................................................ 29

Chapter 4 Transformation in Automotive Sector................................................. 47

Business Challenges in Process Transformation.................................60

Chapter 5 Transformation in Hi-Tech Electronics Industrial Sector................... 67

Chapter 6 Transformation in Process and Industrial Manufacturing Sectors..... 87

Process Automation Potentials....................................................... 95

Chapter 7 Upgradation of Industry 4.0 to Industry 5.0...................................... 107

ODM Original Design Manufacturer

Resource Input Transformation

Feedback and Continuous improvement

FIGURE 1.1 Simple transformation process.

KEY ELEMENTS OF BUSINESS TRANSFORMATION

Manufacturing industries cannot transform successfully unless their individuals

Support and Measure

Review Progress Define Change

Define Goal and Vision

Communicate Change Review Impact Define KPI and Plan

FIGURE 1.2 Organization transformation.

considerable advancement besides learning. Business participants need to discover

Business Process Transformation

FIGURE 1.3 Business process transformation – ERP implementation.

Business process transformation is a deliberate and organized extension of the

TRANSFORMATION IN INDUSTRIAL MANUFACTURING

machine learning transform to the fourth industrial revolution. Understanding the

FUTURE INDUSTRIAL TRANSFORMATION

aid manufacturers to see high returns in the increasingly competitive environment.

Engineering Process Automation

manufacturing and quality control. Assimilation of customer needs and market

Manufacturing Process Automation

integrating real-time dynamic surveillance, quality management, ERP though MES

• Distributed control system

Business Process Automation

Robotic Process Automation

Inspection of Data Interpret and process

Content Extraction, Data extraction from DHF

Virtual Workforce, Auditing of FDA

FIGURE 2.1 RPA role in medical device segments.

RPA technology can considerably assist in automating more applications such as

Practice of RPA in Supply Chain

Digital Process Automation

In this fast-paced smart connected challenging digital transforming world, manufac-

Intelligent Process Automation

NECESSITY FOR PROCESS AUTOMATION

Today’s fast-growing industrial economic pressures have considerably impacted the

organizations are required to comprehend that utilizing modern technology to trans-

PROCESS AUTOMATION TO PROCESS TRANSFORMATION

For manufacturing enterprises, process transformation is the basis of Industry

Adopt the strategy of continuous progress in addition to stepwise progress toward

Value Drivers of Process Transformation