In a feature for MEPCA, Blackbird client Atlas Copco Tools and Industrial Assembly Solutions considers how Industry 5.0 marks a significant progression in the industrial landscape, which focuses on human-centric, sustainable and resilient manufacturing. Whilst Industry 4.0 concentrated on automation and digitalisation, Industry 5.0 complements this with a shift towards a more value-driven manufacturing model, that prioritises the well-being of employees, as well as more environmentally friendly processes and adaptability.
Representing the next step in smart manufacturing, Industry 5.0 focuses on making assembly more human-centric, sustainable and resilient:
- Human-Centric: This emphasises a shift in manufacturing from a ‘technology-first’ approach to placing human expertise and well-being at the forefront of industrial production.
- Sustainability: Industry 5.0 introduces a stronger focus on circular economy principles, energy efficiency and waste reduction to ensure processes align with corporate Environmental Social and Governance (ESG) standards used by investors to measure a business’s impact on society and the environment.
- Resilience: Improved flexibility through the introduction of more agile and adaptable manufacturing systems which are designed to respond effectively to disruptions, such as economic shocks, pandemics and global crises.
Industry 5.0 utilises advanced digital tools as enabling technologies to support human workers rather than replace them, such as Collaborative Robots (Cobots) which are designed to work alongside people in shared workspaces. Cobots enable repetitive, hazardous, or physically demanding tasks to be automated, allowing employees to concentrate on high-value activities such as complex problem-solving, critical thinking and creativity.
For example, Atlas Copco’s Smart Integrated Assembly ecosystem enables both low and high torque tightening strategies to be used with cobots. By using artificial intelligence, cobot-based tooling can also undertake actions such as reading component scans and colour recognition to select specific components and fastener locations. In addition, data from the cobot-based tooling enables full traceability, in Atlas Copco’s drive to Zero Defect Manufacturing (ZDM).
Automating tightening processes also deliver significant productivity benefits, such as the integration of automatic screw feeding technology into robotic workstations. This reduces cycle times to improve productivity and is more human-centric by improving operator well-being and ergonomics, by removing the need for operators to handle minute fasteners.
The rapid adoption of real-time production intelligence and Digital Twins, or virtual replicas of physical assets, is also transforming the industrial sector. Digital Twins provide a dynamic virtual model that mimics assembly processes in real-time, using production data and Artificial Intelligence (AI) to simulate processes, performance and results without disrupting live operations.
AI and ML (Machine Learning) are instrumental in supporting ZDM by proactively eliminating waste and preventing production defects before they occur. These technologies also facilitate e-predictive maintenance and support manufacturers in strategic decision-making. AI and ML are fundamental to Industry 5.0, enabling production processes to be optimised with minimum downtime and improved quality control. Transforming data into actionable insights, the primary applications of AI and ML include predictive maintenance and visual inspection, as well as supply chain optimisation and energy management.
Atlas Copco’s pioneering ALTURE application accelerates the value from data-driven manufacturing by harnessing AI and ML to identify risks in production before they occur. ALTURE uses raw data captured from smart tooling and integrated controllers and analyses this information using AI and an algorithm within the app. This provides users with real-time manufacturing performance notifications, as well as any ‘Not OK’ (NOK) tightening trends and recommendations for process improvement.
Part of Atlas Copco’s VisionTools portfolio, Smart Verification with AI uses AI-enhanced machine vision to automatically check safety-critical joints, sealing and assembly steps in the production process. Enabling new levels of speed, precision, process control and quality control to be achieved in the production process, VisionTools also supports the mission to ZDM.
To improve sustainability, Industry 5.0 emphasises the use of smart materials in manufacturing. Bio-inspired technologies are being increasingly used in assembly to replicate natural structures, resulting in high-performance, lightweight and efficient products. These advanced materials employ additive manufacturing technologies to produce items such as self-healing materials, synthetic textiles and energy-efficient components, which provide increased durability and improve environmental performance.
Atlas Copco’s next-generation PowerFocus 8 advanced controller platform improves efficiency and improves environmental performance by allowing up to 20 wireless assembly tools to be connected via a single interface. PowerFocus 8 decreases energy consumption by reducing the number of tightening controllers required in the assembly process.
Complementing PowerFocus 8, Atlas Copco’s ToolsControl software offers a virtual, server-based digital assembly tool controller system that significantly enhances manufacturing efficiency by removing the need for physical hardware controllers. The main advantages of ToolsControl include increased uptime through intelligent self-healing, less floor space and lower energy consumption, as well as faster, automated tool deployment and reconfiguration.
As a strategic partner, Atlas Copco offers scalable solutions and comprehensive support to manufacturers with the key technologies needed in the drive to Industry 5.0. Transitioning from existing processes to future-ready manufacturing is a complex but essential objective for industry. However, by taking a phased approach, manufacturers can embrace Industry 5.0 and secure sustained, long-term success.
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