Industry 5.0 in aircraft production and MRO: challenges and opportunities

• DOI: 10.1007/s13272-025-00832-3
• Publication Date: 2025-04-06T00:10:29Z
• Authors: Keno Moenck; Julian Koch; Jan-Erik Rath; Lukas Büsch; Johann Gierecker; Falko Kähler; Florian Kalscheuer; Christian Masuhr; Johann Kipping; Philipp Prünte; Daniel Schoepflin; Henrik Eschen; Lukas Antonio Wulff; Rebecca Rodeck; Gerko Wende; Martin Gomse; Thorsten Schüppstuhl

Abstract Globally interconnecting machines, processes, and resources driven by exploring and advancing new technologies defined Industry 4.0 (I4.0), resulting in, e.g., Cyber-Physical Production Systems (CPPS). The aircraft industry particularly struggled with transforming production and Maintenance, Repair, and Overhaul (MRO) processes, replacing humans with machines and automating as well as digitalizing significant parts of their value- and non-value-adding activities. However, in the face of current social and environmental challenges, future industries will need to shift from purely technology-driven to value-driven, working sustainably with resources, including human capital. Together, these approaches constitute the idea of Industry 5.0 (I5.0). On the one hand, the aviation industry faces the challenge that even I4.0 concepts and technologies are not yet fully exploited or implemented. On the other hand, due to the specific characteristics of aircraft production and MRO as well as the environmental impact of the product, a tremendous potential arises regarding placing human well-being back into the center of adding value and decreasing environmental footprint while building an industry that is resilient and fortified against disruptions of this era. In line with the I5.0 terminology, in this work, we outline the challenges and opportunities of integrating I5.0 principles into the aircraft production and MRO industries, focusing specifically on the scope of selected use cases.