Study & Comparative Analysis of Industry 4.0 & Industry 5.0
Author(s):Dr. S. R. Ghatolea ,Sumit Bisenb, Jitendra Telmasarec, Subodh Meshramd, Harshal Sakoree
Affiliation: Mechanical Engineering Department Priyadarshini College of Engineering Nagpur
Page No: 49-54
Volume issue & Publishing Year: Volume 2, Issue 5, May 2025
published on: 2025/05/30
Journal: International Journal of Advanced Multidisciplinary Application.(IJAMA)
ISSN NO: 3048-9350
DOI: https://doi.org/10.5281/zenodo.17523748
Abstract:
The evolution of industrial automation has been characterized by two significant technological transitions: Industry 4.0 and Industry 5.0. Industry 4.0, which involves the integration of cyber-physical systems (CPS), IoT, AI, and Big Data, is largely focused on increasing productivity and operational effectiveness through automation, intelligent factories, and data-driven decision-making. But excessive dependence on automation may restrict flexibility and human responsiveness in manufacturing. To counter this, Industry 5.0 has come into being, advocating human-machine collaboration, sustainability, and flexible manufacturing in favor of a balanced industrial strategy.
This research investigates how Industry 5.0 deviates from Industry 4.0 using the case study of Mecgale Pneumatics Pvt. Ltd. The investigation analyzes the effectiveness of IoT-led predictive maintenance, AI-based analysis, wearable smart devices, and collaborative robots for enhancing industrial efficiency. Although production efficiency is increased by Industry 4.0 technologies like auto-CNC cutting and AI-accelerated quality control, Industry 5.0 considers cobot inclusion, worker protection innovation, and eco-friendly production to create an environment that prioritizes humans during production.
The results indicate that Industry 4.0 enhances automation, minimizes downtime, and increases total productivity, whereas Industry 5.0 provides greater flexibility, personalization, and worker involvement. While automation minimizes the need for human intervention, it is possibly not ideal for low-volume, flexible, or custom production. Industry 5.0 combines automation and human
intelligence, which fosters a sustainable and innovative industrial ecosystem. Therefore, in summary, this research suggests the integration of the efficiency of Industry 4.0 and the human advantage of Industry 5.0. Nevertheless, these challenges as high capital investments, upscaling workers, and integration complexities ought to be overcome through staged adoption to facilitate transitioning to next-generation, sustainable industrial systems smoothly.
Keywords: Industry 4.0, Industry 5.0, Smart Manufacturing, Human-Machine Collaboration, Predictive Maintenance, Cyber-Physical Systems, Industrial Automation, Sustainability
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