Why Industry 5.0 Needs More Human Skills

The concept of Industry 5.0 was introduced by European policymakers and industry analysts. It builds upon the principles of Industry 4.0—such as sensors, data lakes, and robotics—by placing people at the core of advanced manufacturing. Danone emphasizes that AI will only reach its full potential when factory teams are skilled in prompt writing, data interpretation, and working alongside cobots.

This shift isn't just theoretical. Globally, manufacturers are seeking workers who can interpret data, write prompts, or work effectively with AI systems. The challenge lies not only in hiring new talent but also in retraining existing employees.

“The global manufacturing sector is facing a major shortage of skilled workers,” says Vikram Agarwal, Danone’s chief operating officer. “It's crucial for us to invest in training our current workforce so they can actively contribute to Industry 5.0. Technologies like AI and robotics are already changing how we operate, but their real value depends on our people.”

Speeding Delivery of AI Training

Danone’s Academy program breaks down learning into bite-sized modules. Employees receive micro-training sessions on crafting better prompts, analyzing sensor data, and using digital assistants. In-person and virtual workshops at Opole are combined with VR simulations and short five-minute videos distributed across 130 global sites.

The training is rooted in real-world applications. Maintenance teams learn how to describe machine problems to an AI co-pilot. Line supervisors practice using sensor data to optimize production and reduce waste. Digital assistants guide users through standard procedures, identifying issues before they escalate into costly problems.

Opole has already demonstrated success with cutting-edge technology. In 2022, the World Economic Forum recognized it as a Global Lighthouse plant after AI implementation reduced change-over times by one-third and cut water usage by 22 percent. Now, Danone is leveraging the same team—technicians, line leaders, and hourly workers—as peer trainers for colleagues in Brazil, Indonesia, and other regions.

Skill Shift: Why AI Training Is No Longer Optional

AI development continues at a rapid pace, which is why companies like Danone view training as a top priority.

As AI capabilities evolve, so do the skills required to use them. Jobs once considered stable—like customer service, planning, and packaging—are now seeing daily tasks automated or transformed.

Data supports this trend. According to the World Economic Forum, nearly 60% of workers will need new skills by 2027. Around 44% of today’s essential competencies will become outdated in that time. And one in four jobs could either change significantly or disappear entirely.

At the same time, there’s enormous opportunity. McKinsey estimates generative AI could generate $2.6 trillion to $4.4 trillion annually—but only if those managing the systems know how to use them effectively.

How Rivals Are Skilling Up

Danone isn’t the only company linking AI to frontline skills.

Nestlé has launched its own internal large language model named NesGPT, designed to accelerate product development and solve production issues. Thousands of employees—from engineers to packaging experts—earn “prompt certificates” after completing a short internal course.

Unilever is expanding its AI-enhanced Manufacturing System across more than 120 plants globally. Early tests showed double-digit improvements in equipment efficiency.

Procter & Gamble recently collaborated with academic researchers to measure AI’s internal impact. The findings revealed that AI significantly boosted innovation and employee productivity.

Taking the Necessary Next Steps

Upskilling employees goes beyond an HR expense—it’s an investment in resilience. Teams proficient in AI and automation adapt faster during supply chain disruptions, address cybersecurity risks early, and are less likely to leave for more "tech-forward" roles elsewhere. For Danone, introducing these skills at Opole ensures that future upgrades—whether involving cobots, digital twins, or next-generation data platforms—can be implemented smoothly from day one.

“The Academy is just the start,” Agarwal states. “We're also building a new network of 10 pioneering factories to test innovative models of the Digital Factory of the future. Our goal is to redefine human-machine collaboration standards, enabling us to serve customers, consumers, and patients worldwide more effectively.”

AI can reduce costs, increase speed, and enable new products. But the greatest benefits may come from a fundamental factor: equipping people with the skills to make these tools truly valuable.

As businesses rush to enhance their digital capabilities, the winners won’t be determined by the most advanced algorithms, but by the teams who know how to use them effectively from the very first day.

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