A resource for safe and effective troubleshooting from the leaders in simulation training.

Greetings, Troubleshooters! Welcome back to Troubleshooting Thursdays. Today’s topic is Industry 5.0.

Now, we realize that for anyone who’s still trying to wrap their arms around Industry 4.0, the idea that we’re already heading at breakneck speed to yet another total transformation of industrial life might be just a little dizzying.

It does seem that these revolutions are coming at ever-shorter intervals. This one’s still in the future, but—like the Boy Scouts—manufacturers need to be prepared.

How is 5.0 different from 4.0?

We’ve written before about the next industrial revolution. But just to recap—this time it’s personal. That is, Industry 5.0 will be about finding and unlocking hidden value through total digital transformation, which will largely focus on the customer and their ability to customize their purchase experience.

Reaching this goal will involve cooperation between humans and machines, for example, highly trained employees working alongside “cobots.” As Phil Cartwright of the Bristol (UK)-based Centre for Modelling and Simulation, predicts, “Workers will be upskilled to provide value-added tasks during production, leading to mass customization and personalization for customers.”

What will this look like? Well, one example Cartwright gives is currently unfolding in the diabetes-care industry. Right now, people with Type 1 diabetes use a device to measure blood sugar. That device communicates with an insulin pump which delivers insulin into the patient’s bloodstream. It sounds impressive, but it’s still a “one-size-fits-all” solution, which doesn’t take into account individual differences in metabolism, lifestyle, body size or skin thickness, etc. In Industry 5.0, an app will monitor patients’ routines, lifestyles and physical uniqueness and AI technologies will figure out how their bodies will respond to the insulin, and deliver the appropriate dose at the appropriate time.

$100 trillion in value awaits…

Last year, The World Economic Forum released the summary of its two-year Digital Transformation Initiative, launched in 2015.

The Initiative analyzed the impact of digitization in 13 industries along 5 cross-industry topics, to identify the key themes that will allow businesses to harness untapped value via digitization. They calculated that there is $100 trillion of value that digitization can unlock globally over the next decade. “Digital transformation … has immense potential to change consumer lives, create value for business and unlock broader societal benefits.”

They also identified inhibitors to change that can be found in all industries. These obstacles include the fear of cannibalizing existing revenue models, low technology adoption rates across organizations, conservative organizational cultures, and regulatory issues.

Six mission-critical competencies manufacturers will need to navigate Industry 5.0:

Knowing that the untapped value exists is one thing. Tapping into it is another.

Eric Schaeffer, author of Industry X.0: Realizing Digital Value in Industrial Sectors, has identified six competencies businesses must master to prepare for the next revolution (whatever number you assign it). These are the aspects of the IIoT (Industrial Internet of Things) that he identifies as having the greatest potential to impact manufacturing companies:

  1. Synchronizing life cycle clocks. Hardware, products, and machinery have longer life cycles than the software that runs them. Getting these aligned early on saves production problems down the road.
  2. Embedding software intelligence and connectivity in sheet metal products makes them part of the connected production environment. The German company Siemens is a great example of how this can work: they achieved 75% automation in one of their facilities, and as a result reduced the defect rate to 12 per million, at the same time increasing plant output by 8.5 times (without reducing their human workforce).
  3. Using data analytics to gain insights and support decisions. Data is everywhere! Some people estimate that the amount of data on the globe is doubling every two years. There is a goldmine of hidden, as yet unused data that can create value in the customer experience, product performance, workforce efficiency, operational efficiency and optimization of product portfolios. Companies need to leverage these data sources to remain competitive.
  4. Making manufacturing more agile by adopting automation and digitization at every opportunity to increase production and flexibility.
  5. Transitioning to an “as-a-service” business model. In the age of pay per use, car-sharing services, and subscription-based everything, it appears that even manufacturing is headed that way. For example, Kaesar Compressors, an air pump company that sells pumps and compressors, is transitioning to selling “compressed air” as a service.
  6. Creating ecosystems and running them. Manufacturers will need to create “ecosystems” (open networks of strategic business partners with the common aim of driving growth and fostering innovation.) Basically, ecosystems are a company’s “competitiveness network” consisting of cooperators, suppliers, institutions, customers and other stakeholders.

Upskilling your electrical troubleshooters

There’s no doubt that the next industrial revolution has the potential for enormous gains for those who are prepared. But as manufacturing processes become increasingly complex, so will maintenance and repair of production-line equipment. Upskilling maintenance professionals through electrical troubleshooting training remains a critical activity for manufacturers who want to reap the benefits of Industry 5.0.

And that’s it for today, Troubleshooters! Join us again next week, when we launch a new series on what to look for when selecting a training solution.

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