Speaking at the 20th edition of CII Telangana MANEXE 2024, Rucha Nanavati, Chief Information Officer at Mahindra Group, explained how manufacturing will evolve from Industry 4.0 to Industry 5.0, with human-machine collaboration, digital twins, and AI-driven innovations driving manufacturing inefficiencies to efficiencies and the pathway to sustainable growth.

Digitization, automation, and enhancing efficiency through technology have been the focus of Industry 4.0 so far. It underscores the use of the Internet of Things (IoT), Artificial Intelligence (AI), big data, and smart systems to construct interconnected manufacturing environments. The goal was to increase productivity, decrease manual errors, and simplify manufacturing unit processes.

However, automation and manufacturing process optimization is no longer enough. We need to bring humans back into the loop and develop a symbiotic relationship between advanced technologies and human intelligence. In Industry 5.0, we focus on human-machine collaboration, where machines extend the capabilities of humans instead of replacing them. This shift brings in human-centric design, sustainable practices, and safer protocols for a much more holistic approach to manufacturing.  

Human-Machine Interaction: The Core of Industry 5.0

There is a need for increased focus on human-machine interaction beyond the standard manufacturing process. The vision of Mahindra involves cars that are becoming more like 'computers on four wheels' that require continuous interaction between the user and the car’s digital systems. The Industry 5.0 core idea is to personalize and improve user experience using technology, and this user-focused approach embodies this idea.

The Chakan facility is one of the places where Mahindra leveraged digital twins and industrial metaverse technologies. Real-time monitoring and simulation of the production process is achieved by digital twins, which create virtual replicas of physical systems. This capability enables predictive maintenance, which predicts possible failures before they occur, minimizing downtime and increasing efficiency. In addition, the industrial metaverse offers more immersive interactions, wherein engineers and operators can view and debug manufacturing processes in a virtual space before actually making changes to the physical plant.

The Role of Advanced Technologies in Manufacturing

Mahindra has integrated technologies like AI, computer vision, 5G, and edge computing that are changing how it conducts quality assurance and process optimization. One example is computer vision for inspecting paint quality on vehicles where these technologies shine. Traditionally, this inspection process was manual and prone to error by humans. Using computer vision and AI, Mahindra can now achieve up to 95 percent accuracy, identifying defects in seconds and reducing inspection time to ensure high-quality standards.        

Similarly, edge computing is critical for real-time decision-making on the shop floor. As the minimal latency in manufacturing environments is important (where even a slight delay can influence safety or efficiency), edge computing enables the processing of data closer to its source of generation. Such reduction in response times allows for faster implementation of real-time monitoring systems that can immediately address all discrepancies or related issues in the production line.

Another noteworthy aspect is the company’s focus on leveraging 5G technology. 5G with its high speed, and low latency capabilities, is well suited to enable seamless integration of IoT devices and sensors across the plant to exchange real-time data and respond more quickly and accurately to manufacturing challenges. However, as the industry prepares for the arrival of 6G, the possibility for even more sophisticated applications — such as more advanced virtual and augmented reality tools for training and operations — becomes more possible.

Generative AI and Data Utilization  

Using generative AI and Large Language Models (LLMs), shop floor operations can be improved through enhanced decision-making and knowledge accessibility. Generative AI tools implemented by Mahindra scan through massive amounts of historical data, including 'Y-by' sheets, which record production issues over 10 years. The tools enable workers to ask natural language questions about past occurrences, thereby identifying patterns, understanding the causes, and finding solutions faster.

Democratizing knowledge within the organization, and with one single tool, is a great capability. Now, workers who do not have the technical know-how to use complex databases can chat with an AI tool in their native language or dialect, saving them time to get the answers and insights they need faster. Such AI-driven solutions enable a transition from the model of technology that creates barriers for humans, to a human-first technology approach that enhances their experience.

Safety, Security, and IT-OT Integration

The advent of Industry 5.0 also raises awareness of safety and security, especially when we combine Information Technology (IT) and Operational Technology (OT). Previously, manufacturing plants would frequently separate IT from OT to protect against cybersecurity threats. Yet, as more and more of our devices and systems become interconnected, this separation impedes efficiency and real-time decision making.

To solve this challenge, Mahindra is bringing together the IT and the OT systems while undertaking robust cybersecurity measures. The integration of cyber-physical systems (CPS) enables physical processes to be continuously monitored through digital platforms which enables quick response to issues as they occur. It improves the capability of making informed decisions, utilizing real-time data that increases both safety and efficiency on the shop floor.   

It also becomes increasingly important to ensure the safety of human workers as automation and robotics are introduced into these environments. Today's automation systems tend to be isolated areas with stringent safety policies, like shutting down if a human enters a specific area. However, in Industry 5.0 we envision a safe collaborative workspace where robots can work alongside humans. To achieve this, they need to be implemented with advanced sensors, AI-based monitoring systems, and strong safety protocols to prevent accidents and enable smooth interaction.

Embracing a Purpose-Driven Philosophy

The approach of Mahindra is much more than technological advancement and lies in its purpose-driven philosophy. The company’s strategic initiatives show the company’s commitment to improving the community and national growth. For example, the economic goal of India is to increase its GDP contribution of the manufacturing sector from 17% to 25%, a goal that Mahindra is also working towards. The company plans to achieve this through the use of the latest technology in combination with industry partners to bring innovation and efficiency.

Mahindra’s recent successes, including booking 50,000 units of a new model vehicle in just 60 minutes, are testimony to the technology-driven approach that has served it so well. The need for scalable and agile manufacturing capabilities to handle high demand at the quality level is underlined by this remarkable feat. It also underscores the need for continued spending on increasing production capacity and adopting advanced manufacturing technologies to support growth.