Industrija 5.0 – korak ka humaniziranoj gospodarskoj budućnosti

The MeditMaint 2024 Conference, Maintenance 2024, organized by the Croatian Maintenance Society (HDO), was held from May 13th to 16th in the conference hall of the Lone Hotel in Rovinj. The focus of the Conference was on Industry 5.0 and the industrial philosophy of Zero Waste, Zero Defects, and Zero Accidents.

As is well known, the previous Industry 4.0, or the fourth industrial revolution, focused on digitization, automation, and the integration of technologies such as IoT, AI, and Big Data into manufacturing. Industry 5.0 encompasses further development in the collaboration between humans and robots, focusing on the humanization of technology and enhancing the cooperation between humans and machines. In Industry 5.0, technology adapts to human needs and working conditions, rather than humans adapting to technology. There is a greater emphasis on customizing products to the individual needs and desires of consumers, which involves more flexible production processes capable of quickly responding to changes in demand.

From Croatian Practice
These were also the main themes of the MeditMaint 2024 Conference, as well as the EFNMS workshops led by scientists and experts in maintenance and asset management from the Netherlands and Greece. Approximately 120 participants, including speakers, keynote speakers, and exhibitors from Croatia, Bosnia and Herzegovina, Slovenia, the Netherlands, Spain, Austria, Greece, and even as far as Thailand, attended the Conference.
The Conference was opened with a welcome speech and drinks by the president of HDO, Drago Frković, dipl. ing. mech., on Monday evening, May 13th.

The next morning, after the opening of the partner exhibition of Croatian maintainers and asset managers, he handed over the floor to Prof. PhD. Igor Kuzle, president of the International Program and Review Committee. “The MeditMaint Conference is focused on new technologies, trends, and experts who conduct research and implement best practices in maintenance and asset management. MeditMaint has a rich tradition of presenting scientific and professional research, exchanging ideas, and networking experts,” said Prof. Igor Kuzle, among other things.

The practice of managing multi-apartment buildings in the Republic of Croatia has shown some shortcomings that need to be corrected. Although laws in this area were adopted and adapted from the best practices of Germany and Austria after Croatia gained independence, it has proven difficult to carry out necessary interventions in some circumstances. Mr. sc. Željko Uhlir, a civil engineer and secretary in the Ministry of Physical Planning, Construction, and State Assets, addressed this issue in the first plenary lecture. The problem is complex, as building management falls under the jurisdiction of several ministries and municipal services. A significant innovation is the introduction of the legal category “community of co-owners,” which will receive legal personality and a tax ID number, helping co-owners exercise their rights and making them a single entity for state and municipal services.

Prof. PhD Diego Galar from Bilbao, Spain, could not attend the Conference due to injury. His lecture on the topic “Industrial Metaverse: A Playground for Digital Twins Accelerating Maintenance Processes” was held online. Digital twins are sophisticated digital models that replicate physical objects, processes, or systems in real time. These digital models enable monitoring, analysis, and optimization of technical systems’ performance. In the context of technical system maintenance, digital twins play a key role in improving efficiency, reducing costs, and increasing reliability. By using advanced analytics and AI, digital twins can predict failures and determine the optimal time for maintenance.

„Strength of Automation and Modernization in Driving Operational Excellence“ by Tatjana Ilić, a member of the Management Board of Pliva and Chief Operating Officer in Zagreb, discussed the strength of automation in driving operational excellence, and Aleksandar Simović, director of brewery operations at Zagrebačka pivovara, presented the „Connected Worker platform in brewing“. In a turbulent business environment, achieving operational excellence is crucial for organizations to remain competitive and adapt to changing market demands. Technological integration plays a key role in driving operational excellence transformations, enabling companies to optimize processes, improve decision-making, and foster a culture of continuous improvement. By implementing state-of-the-art robotic process automation and AI technologies, daily processes can be fully automated, freeing up human resources to focus on value-added activities.

How to bring a brewery into the 21st century? There are many ways, and Zagrebačka pivovara chose top-notch technology and automation, investing in state-of-the-art machinery. Simultaneously, they invest in employees and experts. Zagrebačka pivovara has also introduced a platform for connecting and informing employees. The platform tracks and controls all processes and procedures in the brewery operations. – Using the application on their phones and tablets, operators have access to all standards, procedures, and processes relevant to their role, as well as an overview of the status of all work orders for their machine, said mr. sc. Simović.

The Role of AI in Asset Management
„It is time to reconsider the roles of the human factor, resilience, and sustainability in an increasingly smart technological environment,“ asserted Mr. sc. Jan Stoker, a Dutch asset management expert, in his presentation. How to prepare, educate, train, and motivate current and future experts, and how organizations should view digital readiness, the role of AI, and how asset management responds to many of today’s climate and geopolitical issues. It is hard to imagine 21st-century asset management without data and people. Although Industry 5.0 is a relatively new concept, its main features already exist. Literature analysis on Industry 5.0 shows a lot of uncertainty about what it will bring and how exactly it will change business, as well as how it will potentially break down barriers between the real and virtual worlds.

PhD. Gordan Badurina, Chief Operating Officer and member of the Management Board of PharmaS, addressed the challenges of the pharmaceutical industry. In recent years, Europe has faced shortages of basic medicines. Although the pharmaceutical industry is one of the most profitable economic activities, problems with raw material supply (Covid, wars, closing of shipping routes…) and high industry regulation (legal regulations, ecological requirements) often disrupt supply chains. The generic drugs industry faces special problems because drug prices do not follow the rise in prices of raw materials, energy, and transportation.

Siniša Brajković, aftermarket sales manager at SKF Croatia, shared experiences from the world’s largest manufacturer of ball bearings, focusing on digital transformation trends, the application of industrial internet, and AI. New technology brings new models of asset management and maintenance.
This was followed by a series of professional presentations, often from practice, and one scientific study.

Vinko Benković and Ivan Pavičić presented “Implementation of IBM Cloud Pak for Data in HOPS Data Warehouse,” showcasing the existing data warehouse upgraded with the new version of IBM’s Cloud Pak for Data system.

Andrej Androjna from Quantum Consulting presented the upgrade of maintenance processes at Salonit Anhovo d.d. (now Alpacem Cement d.d.). The consulting project supported the systematic preparation and gradual implementation of maintenance process upgrades. The company has become a Slovenian center of excellence in the production, development, application, and supply of high-quality, environmentally friendly construction materials based on mineral raw materials.

Janez Tomažin discussed the possibilities and need for certification in asset management developed within the GFMAM (Global Forum on Maintenance and Asset Management). Certifications ensure that asset management professionals possess the necessary knowledge and skills. They cover a wide range of topics, including financial statement analysis, valuation, portfolio management, and ethics. Clients seek asset managers they can trust to responsibly and effectively manage their assets.

Lovro Frković (co-authors Boris Ćosić, Tomislav Pukšec, Nikola Vladimir) presented „Smart Charging: Improving Competitiveness of Battery-Powered Electric Ferries in the Day-Ahead Electricity Market.“ In Croatia, there are already several vessels powered by electricity, and in Norway, the first electric car ferry operates between Lavik and Oppedal (distance 5.7 km), creating zero emissions and minimal noise. How to ensure the most economical battery charging, i.e., exchange of full/empty batteries at the lowest electricity prices?

Luka Dermišek presented „Increased Prevention – Maximum Safety of the Croatian Transport System.“ Due to the recognition of potential deficiencies, pipelines are monitored for objects, routes, flows, quantities, pressures, impermeability, corrosion, insulation… Sensors, software, hardware, drones, physical patrols are used for this purpose… The goal is to achieve zero defects and zero accidents.

Darko Virovac (co-authors Silvestar Špehar, Roman Babić) presented „Factors Influencing the Duration of Major Aircraft Inspections.“ Tasks and inspection schedules are determined by the manufacturer, and besides the number of take-offs and landings, flight hours, aircraft age… weather conditions, rain, ice, salt in the air, volcanic activity, microorganisms also affect the frequency of inspections and maintenance.

Mato Siladić presented the topic “Grubišno Polje” compressor station for underground gas storage. Exhausted gas or oil fields are used for underground gas storage today. These are strategic facilities for gas reserves and energy independence. The central object of the plant is a compressor station that serves for filtration, compression, storage or distribution of gas, and the heart of the compression station is the KU-21 package unit.

“AdBlue” from plant to VDA license is a topic that was dealt with by Tonća Ćaleta Prolić (co-author Samir Kulenović). AdBlue is used in selective catalytic reduction (SCR) systems that are installed in modern diesel engines to meet strict European and global emission standards, such as the Euro 6 standard. A significant project of INA Maziva d.o.o. was the construction of the plant, production and successful final VDA audit of the German Association for the Automotive Industry with the aim of obtaining a worldwide certificate and license.

Philosophy of Industry 5.0

Two papers were presented by prof. PhD. Surapol Raadnui from KMUTNB University in Bangkok, Thailand (co-authors Sontinan Intasonti, Pavin Tawichsri, Sithipong Mahathanabodee). The topics were „Preliminary assessment of off-line pollution monitoring sensors for used oil analysis“, and „Preliminary assessment of wear product analysis of grease-lubricated helical gears“. In the first presentation, electrical capacitive measurement of lubrication oil degradation in a technical system was presented. The second paper describes a preliminary experimental investigation of a pair of spiral gears that, under certain conditions, work without lubrication and with lubrication with clean and contaminated oil.       

For several years in a row, HDO awards the best presentations of works at the MeditMaint Consultation. The judging commission composed of prof. Ph.D. Igor Kuzle and Prof. Ph.D. Toma Udiljak decided that this year the award will be shared by two authors: Dr. sc. Mato Siladić, S.C.A.N. Company, Zagreb for the topic Compressor station for underground gas storage “Grubišno Polje” and prof. Ph.D. Surapol Raadnui, et al., KMUTNB, Bangkok, Thailand for the topic Preliminary Evaluation of Wear Product Analysis of Grease Lubricated Helical Gears. The prize is exemption from the registration fee for the MeditMaint 2025 Consultation – Maintenance 2025.

It is also worth noting the presentations of the presenters at the MeditMaint 2024 Consultation.

The company Feromihin d.o.o. specializes in complex consulting, procurement, installation, maintenance and servicing of transportation systems for oil and gas pipelines. At the Consultation, they presented the AMS (Asset Management System) application as an advanced solution for predictive analytics of maintenance strategy and digitization in the oil and gas industry.

Little needs to be said about Daikin. Branko Glumac presented the latest technological solutions. Daikin is the world leader in air conditioning solutions that have always been shaped by revolutionary ideas, technological innovations and dedicated people. This year Daikin celebrates 100 years of existence.

Joško Ivankov from qCode IT d.o.o. introduced the WorkTrek platform. It is a cloud platform that helps maintenance teams, asset and facility managers and technicians streamline and digitize their field work, maintenance and asset management operations. It consolidates asset data and tracks maintenance activities, paperwork, service history, spare parts, asset condition and pricing.

How industrial augmented reality can enhance process efficiency and safety was presented by Alexander Loidolt from WIEWER GmbH. After thirty years in various executive sales and delivery positions at IBM, Mr. Loidolt decided to invest in a startup, bringing his experience to it. The augmented reality solutions for companies to connect people with information and their environment, along with an insightful presentation on the power of 3D scanning for AR applications, garnered well-deserved attention from the Conference participants. VIEWAR works on standard browsers, smartphones, tablets, and HMD devices.

According to Željko Azenić, GEWINDE d.o.o. is registered for manufacturing and wholesale trade. It is based in Osijek and has a representative office in Zagreb. They specialize in sealing materials, industrial valves, compressors, SMC pneumatics, pumps, and WIDOS polymer pipe welding. They partner with numerous well-known companies such as Boge, SMC, Valpress Valba, and Crane.

INSTRO d.o.o. primarily engages in sales, measurement execution, analysis, and NDT inspection services for various industries (steel mills, foundries, chemicals, plastics, glass, pharmaceuticals, food), as well as for scientific research organizations (universities, institutes, laboratories), healthcare organizations (clinics, hospitals), and public services. They deal in sales, service, and engineering in the following areas: technical diagnostics, element analysis, vacuum, radiation measurements, and non-destructive testing.

In the oil and gas industry, FASEK d.o.o. specializes in the supply of equipment and the provision of regular and emergency maintenance services, specialized pipeline maintenance services, and the protection of infrastructure objects using special coatings. Their wide range of process valves, represented by companies such as SAMSON, ARI ARMATUREN, and KUEHME, makes them present in about 200 manufacturing companies from various sectors of the process industry.

Besides presentations by keynote speakers, the central part of the MeditMaint 2024 Conference included Workshops related to Industry 5.0. Topics included the adoption of the philosophy of zero defects, zero failures, zero accidents, and asset management and maintenance 5.0; practical transition and implementation strategies. The workshops were led by managers and scientists George Scroubelos, Panos Konstantinou from Greece, and Jan Stoker from the Netherlands. The modern philosophy of Industry 5.0 places humans at the center of digitalization, automation, robotics, and artificial intelligence with a significant emphasis on the business philosophy of Zero Waste, Zero Defects, and Zero Accidents. The advantages of Industry 5.0 include improved efficiency, as collaboration between humans and machines can lead to significant improvements in efficiency and productivity. Additionally, greater adaptability: the ability to respond quickly to changes in market demands and consumer preferences. A better working environment: focusing on the human component improves working conditions, reduces stress, and increases worker satisfaction. Sustainability: integrating sustainable practices reduces the industry’s environmental footprint.

For the successful implementation of Industry 5.0, organizations need to invest in employee training and development to ensure that workers have the necessary skills to work with advanced technologies. Furthermore, they need to develop flexible and adaptable production processes: enabling quick adjustments to changes in market conditions, focusing on waste reduction, and resource savings through efficient production methods. Industry 5.0 represents a step towards a more humanized, adaptable, and sustainable industrial future, where technology supports human creativity and innovation. Zero Waste is a principle aimed at eliminating waste through efficient resource use and material reuse, Zero Defects emphasizes the importance of achieving perfection in production through error prevention and continuous process improvement, and Zero Accidents aims to achieve maximum workplace safety. The goal is to eliminate all accidents and injuries through proactive safety measures. These were some of the highlights discussed in various contexts during the workshops.

Industry 5.0 in Action

The last day of the Conference was dedicated to fieldwork and a visit to the Rockwool Adriatic d.o.o. factory in the Pićan Jug industrial zone in Potpićan. This visit was the highlight of the Conference, as many principles of Industry 5.0 were visible in action. The very kind hosts guided the Conference participants through the factory’s warehouses and plants, introducing them to the innovative technology for producing insulation material from eruptive-origin stone. The health and environmental protection rules were very impressive, as were other Industry 5.0 principles. Maintenance is largely predictive and preventive, with factory employees monitoring automation, robots, and product quality. On tedious quality inspection tasks, employees rotate frequently, and the protection of employees and visitors is very strict, starting in the parking lot where cars are parked rear-first to avoid maneuvering in case of evacuation. Vehicle pathways are strictly separated from pedestrian pathways, and where they intersect, there are crosswalks. Protective gear (vests, caps, safety glasses) is mandatory for everyone, and almost everything is recycled: stone material scraps, potentially substandard products, stone dust, iron derivatives from stone melting are separated and sold; overall, there is almost no waste as all materials are recycled in some way. The environmental impact is minimal.

This year’s MeditMaint 2024 Conference was held under the patronage of the Ministry of Physical Planning, Construction, and State Assets of the Republic of Croatia.