Operator 5.0 in Smart Manufacturing: a Literature Review
1
Virumaa Innovation Centre of Digitalisation and Green Technologies, TalTech Virumaa College, Estonia
2
Department of Mechanical and Industrial Engineering, Tallinn University of Technology, School of Engineering, Estonia
Submission date: 2026-02-06
Final revision date: 2026-03-26
Acceptance date: 2026-03-27
Online publication date: 2026-04-16
Corresponding author
Vjatsheslav Kekshin
Virumaa Innovation Centre of Digitalisation and Green Technologies, TalTech Virumaa College, Järveküla tee 75, 30322, Kohtla-Järve, Estonia
Virumaa Innovation Centre of Digitalisation and Green Technologies, TalTech Virumaa College, Järveküla tee 75, 30322, Kohtla-Järve, Estonia
KEYWORDS
TOPICS
ABSTRACT
The operator plays an integral role in various stages of production processes. Their work is closely connected to the development and integration of new technologies in manufacturing, which they must adapt to and incorporate into their daily tasks. The transition from Industry 4.0 to Industry 5.0 has a global impact on operators, transforming them from Operator 4.0 into Operator 5.0. This process affects many aspects of the operator’s development, such as education, professionalism, endurance, safety, health protection, and the working environment, as well as the ability to perform tasks sustainably and with high quality. This literature review article describes the main approaches to the transition from Operator 4.0 to Operator 5.0 in smart manufacturing. In this new transition, numerous tasks arise that need to be structured into a unified solution.
REFERENCES (53)
1.
LONGO F., NICOLETTI L., PADOVANO A., 2022, New Perspectives and Results for Smart Operators in Industry 4.0: A Humancentered Approach, Computers & Industrial Engineering 163, 107824, https://doi.org/10.1016/j.cie.....
2.
CIMINO A., ELBASHEER M., LONGO F., NICOLETTI L., PADOVANO A., 2023, Empowering Field Operators in Manufacturing: A Prospective Towards Industry 5.0., Procedia Computer Science 217, 1948–1953, https://doi.org/10.1016/j.proc....
3.
ROMERO D., BERNUS P., NORAN O., STAHRE J., FAST-BERGLUND Å., 2016, The Operator 4.0: Human Cyber-Physical Systems & Adaptive Automation Towards Human-Automation Symbiosis Work Systems, Production Management Initiatives for a Sustainable World, Springer, IFIP, AICT 488, 677–686.
4.
GALLOA T., SANTOLAMAZZA A., 2021, Industry 4.0 And Human Factor: How is Technology Changing the Role of the Maintenance Operator?, Procedia Computer Science 180, 388–393. https://doi.org/10.1016/j.proc....
5.
GLADYSZ B., TUAN-ANH T., ROMERO D., ERP T.V., ABONYI J., RUPPERT T., 2023, Current Development on the Operator 4.0 and Transition Towards the Operator 5.0: A Systematic Literature Review in Light of Industry 5.0., Journal of Manufacturing Systems 70, 160–185, https://doi.org/10.1016/j.jmsy....
6.
ROMERO D., STAHRE J., 2021, Towards the Resilient Operator 5.0: The Future of Work in Smart Resilient Manufacturing Systems, Procedia CIRP, 104, 1089–1094.
7.
ZOLOTOVA I., PAPCUN P., KAJATI E., MISKUF M., MOCNEJ J., 2020, Smart and Cognitive Solutions for Operator 4.0: Laboratory H-CPPS Case Studies, Computer and Industrial Engineering, 139, 105471.
8.
ROMERO D., et al., 2016, Towards an Operator 4.0 Typology: a Humancentric Perspective on the Fourth Industrial Revolution Technologies, CIE 2016 46th Int. Conf. Comput. Ind. Eng.
9.
THAKUR H.K., 2021, Research Methodology in Social Sciences, New Delhi: Corvette Press, 36–52.
11.
MOURTZIS D., 2021, Towards the 5th Industrial Revolution: a Literature Review and a Framework for Process Optimization Based on Big Data Analytics and Semantics, Journal of Machine Engineering, 21/3, 5–39, https://doi.org/10.36897/jme/1....
12.
FABIO G., GIUDITTA C., MARGHERITA P., RAFFAELI R., 2025, A Human-Centric Methodology for the Co Evolution of Operators’ Skills, Digital Tools and User Interfaces to Support the Operator 4.0., Robotics and Computer–Integrated Manufacturing 91102854.
13.
MARK P. TAYLOR, PETER BOXALL, JOHN J. J. CHEN, XUN XU, ANGELA LIEW, ADEBAYO ADENIJI. Operator 4.0 or Maker 1.0? Exploring the implications of Industrie 4.0 for innovation, safety and quality of work in small economies and enterprises” Computers & industrial engineering, 139: 105486, 2020.
14.
LONGO F., MIRABELLI G., NICOLETTI L., SOLINA V., 2022, An Ontology-Based, General-Purpose and Industry 4.0-Ready Architecture for Supporting the Smart Operator (Part I – Mixed Reality Case), Journal of Manufacturing Systems 64, 594–612, https://doi.org/10.1016/j.jmsy....
15.
VALENTINA D.P., VALENTINA D.S., SALVATORE M., STEFANO R., 2021, Smart Operators: How Industry 4.0 is Affecting the Worker’s Performance in Manufacturing Contexts, Procedia Computer Science, 180, 958–967, https://doi.org/10.1016/j.proc....
16.
OLIVERI L.M., LO IACONO N., CHIACCHIO F., FACCHINI F., MOSSA G., 2024, A Decision Support System Tailored to the Maintenance Activities of Industry 5.0 Operators, PapersOnLine, 58/8, 186–191, https://doi.org/10.1016/j.ifac....
17.
BECHINIE C., ZAFARI S., KROENINGER L., PUTHENKALAM J., TSCHELIGI M., 2024, Toward Human-Centered Intelligent Assistance System in Manufacturing: Challenges and Potentials for Operator 5.0, Procedia Computer Science, 232, 1584–1596, https://doi.org/10.1016/j.proc....
18.
HATTINGER M., STYLIDIS K., 2023, Transforming Quality 4.0 Towards Resilient Operator 5.0 Needs, Procedia CIRP, 120, 1600–1605, https://doi.org/10.1016/j.proc....
19.
PADOVANO A., CARDAMONE M., KLAESS J., 2024, Empowering Operator 5.0: Human-Centric Design of an Augmented Reality Tool for a Learning Factory, PapersOnLine 58–8, 180–185,,https://doi.org/10.1016/j.ifac....
20.
KHEIRI S.K., VAHEDI Z., SUN H., MEGAHED F.M., CAVUOTO L.A., 2023, Human Reliability Modeling in Occupational Environments Toward a Safe and Productive Operator 4.0, International Journal of Industrial Ergonomics, 97, 103479, https://doi.org/10.1016/j.ergo....
21.
CICCARELLI M., PAPETTI A., GERMANI M., 2023, Exploring How New Industrial Paradigms Affect the Workforce: A Literature Review of Operator 4.0, Journal of Manufacturing Systems, 70, 464–483, https://doi.org/10.1016/j.jmsy....
22.
GAZZANEO L., PADOVANO A., UMBRELLO S., 2020, Designing Smart Operator 4.0 for Human Values: A Value Sensitive Design Approach, Procedia Manufacturing 42, 219–226, https://doi.org/10.1016/j.prom....
23.
VITTI M., PADOVANO A., FACCHINI F., A Review on Cognitive Workload for Industry 5.0. 2025, https://doi.org/10.1016/j.cie.....
24.
MONFERDINI L., TEBALDI L., BOTTANI E., 2025, From Industry 4.0 To Industry 5.0: Opportunities, Challenges, and Future Perspectives in Logistics, Procedia Computer Science, 253, 2941–2950.
25.
SBARAGLI A., TOMELLERI F., PICARIELLO F., PICARIELLO E., PILATI F., 2024, Safe Operator 5.0 Digital Architecture: Towards Resilient Human-Centric Manufacturing Systems, IFAC PapersOnLine 58–19, 265–270.
26.
CIMINO A., LONGO F., MIRABELLI G., SOLINA V., VERTERAMO S.V., 2024, An Ontology-Based, General-Purpose and Industry 4.0-Ready Architecture for Supporting the Smart Operator (Part II – Virtual Reality Case), Journal of Manufacturing Systems. 73, 52–64, https://doi.org/10.1016/j.jmsy....
27.
SEGURA A., DIEZ H.V., BARANDIARAN I., ARBELAIZ A., ALVAREZ H., SIMOES B., POSADA J., GARCIA-ALONSO A., UGARTE R., 2020, Visual Computing Technologies to Support the Operator 4.0., Computers & Industrial Engineering, 139, 105550, https://doi.org/10.1016/j.cie.....
28.
CIMINI C., LAGORIO A., ROMERO D., CAVALIERI S., STAHRE J., 2020, Smart Logistics and the Logistics Operator 4.0., IFAC PapersOnLine, 53–2, 10615–10620.
29.
LÖCKLINA A., JUNGA T., JAZDIA N., RUPPERTB T., WEYRICHA M., 2021, Architecture of a Human- Digital Twin as Common Interface for Operator 4.0 Applications, Procedia CIRP, 104, 458–463.
30.
BATTINI D., BERTI N., CELLA C., FARONI M., GARZA P., GUIDOLIN M., MOOS S., OLIVETTI E.C., REGGIANI M., SARDINI E., TONELLO S., 2024, Designing the Operator of the Future: The Architecture of Human Digital Twin Systems, IFAC PapersOnLine 58–19, 355–360.
31.
STRÖBEL R., MAU M., DIEBOLD M., PUCHTA A., FLEISCHER J., 2025, Review of Process Monitoring and Anomaly Detection Applications for CNC Milling Machines in Highly Flexible Production, Journal of Machine Engineering, 25/4, 33–52.
32.
HOLLAS L., SCHENKE C.-C., HELLMICH A., 2023, Approach of a Model Extension for Virtual Commissioning to Predict Energy Consumption of Production Systems, Journal of Machine Engineering, 23/4, 77–88.
33.
GREGORI F., PAPETTI A., PANDOLFI M., PERUZZINI M., GERMANI M., 2017, Digital Manufacturing Systems: A Framework to Improve Social Sustainability of a Production Site, Procedia CIRP, 63, 436–442, https://doi.org/10.1016/j.proc....
34.
PACAUX-LEMOINE M.P., TRENTESAUX D., ZAMBRANO REY G., MILLOT P., 2017, Designing Intelligent Manufacturing Systems Through Human-Machine Cooperation Principles: A Human-Centered Approach, Comput. Ind. Eng., 111, 581–595, https://doi.org/10.1016/j.cie.....
35.
FUSKO M., RAKYTA M., KRAJCOVIC M., et al 2018, Basics of Designing Maintenance Processes in Industry 4.0., MM Sci. J.,:2252–2259, https://doi.org/10.17973/MMSJ.....
36.
DIAMOND J., 2011, Collapse: How Societies Choose to Fail of Succeed, Second Edition; Viking Press.
37.
LENG J., SHA W., WANG B., ZHENG P., ZHUANG C., LIU Q., WANG L., 2022, Industry 5.0: Prospect and Retrospect, Journal of Manufacturing Systems, 65, 279-295.
38.
LU Y., ZHENG H., CHAND S., XIA W., LIU Z., XU X., BAO J., 2022, Outlook on Human 1596 Manufacturing Towards Industry 5.0., Journal of Manufacturing Systems, 62, 612–627.
39.
ROMERO D., STAHRE J., 2021, Towards the Resilient Operator 5.0: the Future of Work in Smartresilient Manufacturing Systems, Procedia CIRP, 104,1089–94.
40.
II Consortium, 2022, Compilation of Views on The Smart Manufacturing Industry, URL https://www.iiconsortium. org/wpcontent/uploads/sites/2/2022/07/GIO Smart-Manufacturing, 2022-06-15.pdf.
41.
II Consortium, 2022, Digital Transformation in Manufacturing: Key Insights Future Trends, URL https://www. iiconsortium.org/pdf/IICDX-in-Manufacturing Insights-Trends-Tech-Brief.pdf.
42.
PEREIRA C., ALVES A.C., AREZES E.P., 2023, Augmented Reality in a Lean Workplace at Smart Factories: A Case Study, Applied Sciences, 13, fasc., 16, 9120.
43.
ROMERO D., BERNUS P., NORAN O., STAHRE J., BERGLUND AF., 2016, The Operator 4.0: Human Cyber-Physical Systems & Adaptive Automation Towards Humanautomation Symbiosis Work Systems, IFIP Adv. Inf. Commun. Technol., 488:677–86.
44.
JAIME A., OSORIO-SANABRIA M.A., BERNAL TORRES D.Y., 2026, Similarities and Differences Between Industry 4.0 And Industry 5.0, Towards a transitioning model, https://doi.org/10.1016/j.jik.....
45.
RORATO FOGACA D., GRIJALVO M., SACOMANO NETO M., 2025, What Are Industry 4.0 And Industry 5.0 All About?, An Integrative Institutional Model for the New Industrial Paradigms, https://doi.org/10.3390/admsci....
46.
GIL G., JOSE M., VILA-GUTIERREZA., JESUS M., MARTIN-GOMEZ, MANUEL A., MARTIN-GOMEZ, MANUEL A., 2024, From Industry 4.0 to Industry 5.0: A Study and Perspectives on Technological Evolution.
47.
NEUMANN W.P., WINKELHAUS S., GROSSE E.H., GLOCK C.H., 2021, Industry 4.0 and the Human Factor—a Systems Framework and Analysis Methodology for Successful Development, International Journal of Production Economics, 233, 1079929.
48.
SONY M., 2020, Pros and Cons of Implementing Industry 4.0 for the Organizations: A Review and Synthesis of Evidence, Production & Manufacturing Research, 8/1, 244–272.
49.
ZORZENON, R., LIZARELLI, F. L., DE A., MOURA D.B.A., 2022, What is the Potential Impact of Industry 4.0 on Health and Safety at Work? Safety Science, 153, 105802.
50.
SIDHARTHA S., SOUMYATANU MUKHERJEE P., CHENG T.C.E., 2024, Optimal Investment Decision for Industry 4.0 Under Uncertainties of Capability and Competence Building for Managing Supply Chain Risks, https://doi.org/10.1016/j.ijpe....
51.
KHAN I.S., AHMAD M.O., MAJAVA J., 2023, Industry 4.0 Innovations and Their Implications: An Evaluation from Sustainable Development Perspective, https://doi.org/10.1016/j.jcle....
52.
HERMAWATI S., CORREA R., MOHAN M., LAWSON G., HOUGHTON R., 2024, Defining Human- Centricity in Industry 5.0 and Assessing the Readiness of Ergonomics/Human Factors Communities in the UK, Ergonomics, 1–20.
53.
GHOBAKHLOO M., IRANMANESH M., FATHI M., REJEB A., FOROUGHI B., NIKBIN D., 2024, Beyond Industry 4.0: A Systematic Review of Industry 5.0 Technologies and Implications for Social, Environmental and Economic Sustainability, Asia-Pac. J. Bus. Adm. ahead-of-print.
| eISSN: | 2391-8071 |
| ISSN: | 1895-7595 |
We process personal data collected when visiting the website. The function of obtaining information about users and their behavior is carried out by voluntarily entered information in forms and saving cookies in end devices. Data, including cookies, are used to provide services, improve the user experience and to analyze the traffic in accordance with the Privacy policy. Data are also collected and processed by Google Analytics tool (more).
You can change cookies settings in your browser. Restricted use of cookies in the browser configuration may affect some functionalities of the website.
You can change cookies settings in your browser. Restricted use of cookies in the browser configuration may affect some functionalities of the website.
