Industry 5.0, AI and India: Schneider Electric’s Barbara Frei is smarter in manufacturing plants

Now, artificial intelligence (AI) is expected to drive the next industrial revolution. The factory is already automated enough, but AI-powered manufacturing will soon bring about major changes and become the center stage in the Industry 5.0 ERA. Unlike Industry 4.0, which focuses on automation, connectivity and data-driven decision-making, Industry 5.0 combines human intelligence with advanced technologies such as AI, robotics and open automation, thereby promoting a more agile, adaptable and sustainable industrial ecosystem.

Barbara FriarEVP – Schneider Electric’s Industrial Automation, in Debashis Sarkarshared key insights into the next industrial revolution. extract.

Q: AI is increasingly integrated into industrial automation. How do you see its role evolving?

one: AI has been an integral part of industrial solutions for many years. About 17 years ago, we introduced products with embedded AI, including machine learning and advanced process control. Today, AI has evolved to cover real-time edge computing and generation of AI.

In particular, the generated AI has great engineering potential. In the future, engineers may no longer need to manually design systems on large screens. Instead, they might simply enter application requirements and AI will generate optimized automation solutions. This shift can redefine how industrial automation can be implemented, resulting in more efficient and innovative.

Additionally, the widespread adoption of AI and machine learning (ML) for predictive maintenance and intelligent decision making is changing the industry. AI-powered machine vision is addressing the shortage of nearly 8 million workers in their QA role. In addition to quality control, AI reduces engineering time and improves operational efficiency, driven by the need to increase productivity and make up for labor shortages.

Q: Global industries are rapidly adopting AI and automation. Do you think this transition is driven by necessary or external pressure?

one: As businesses seek to increase productivity, address labor shortages and remain competitive in an evolving industrial environment, the adoption of AI and automation is driven primarily by necessities. External factors such as regulatory policies and sustainability goals play a role, but core drivers still need to improve efficiency, agility and resilience.

One of the most important AI applications today is visual inspection, improving quality control and reducing errors in manufacturing. In addition, industrial decarbonization is accelerating the adoption of AI. More than 40% of the learning in the industrial sector, including buildings and factories, has been approved globally, making it the biggest contributor to climate change. AI-driven energy optimization and automation technologies are crucial to reduce emissions, improve resource efficiency and achieve sustainability goals.

In addition to energy management, the Industrial Internet (IIOT) is changing operations by enabling real-time data exchange, while collaborative robots (COBOTS) are redefining human-computer interaction. The convergence of artificial intelligence, robotics and energy technologies (plus advanced data management) is revolutionizing the industry, driving sustainability and competitiveness in the era of digital transformation.

Q: What are the key global trends in industrial automation over the past year? What is the comparison between India’s adoption?

one: Over the past year, industrial automation has been affected by key trends such as AI and ML-driven predictive maintenance, industrial decarbonization, the increase in adoption of IIOT and the adoption of collaborative robots, and the shift to software-driven open automation to increase flexibility and efficiency. Sustainability remains a top priority, automating optimization of resources and reducing emissions. Although digital transformation is crucial to competitiveness, a McKinsey study found that less than 26% of companies successfully implemented the company due to organizational challenges such as cross-functional collaboration. But adoption is improving as leadership teams actively promote digital initiatives. In India, the adoption of automation is accelerating under the impetus of government initiatives such as “Made in India”.

Q: You mentioned leadership support. Do you think you are intentionally resisting automation and AI due to fear of unemployment or lack of expertise?

one: At Schneider Electric, we believe successful automation and AI implementation go hand in hand with high skills. When organizations launch these projects, it is crucial to invest in continuous learning so that employees understand not only the possibilities, but also the limitations of these technologies.

We focus on providing the right skills to our employees to effectively drive this transformation to ensure consistency across the organization. A clear vision is essential – an industrial landscape that enables employees to adapt and thrive. This approach is at the heart of Industry 5.0, where technology and human expertise work together to create sustainable and efficient systems.

Q: Open automation is growing. What do you think about this?

one: The driving force behind open automation is undeniable and its impact on the industry is transformative. As the industry contributes nearly 40% of global emissions, optimization, digitalization and electrification operations are critical to addressing sustainability challenges. Despite the increased efficiency of digitization and automation, many existing automation solutions are proprietary, limiting IT-level data access and limiting integration capabilities.

Open automation bridges this gap by seamlessly integrating data from operational technology (OT) onto it. Since about 80% of the factory data is generated through automation, Open Automation enables companies to coordinate systems and unhardware from software at different levels. This flexibility allows software updates to be hardware-free, ensuring agility, reducing unnecessary costs, and improving overall efficiency.

Q: How do you view India’s future in automation and AI?

one: India has a huge opportunity to become a global leader in industrial automation driven by artificial intelligence, digitalization and open automation. The country has made great progress in high-skilling, investing in digitalization and adopting advanced technologies, positioning itself for the future of smart manufacturing. But for this transformation to be successful, a highly skilled workforce, sustainable energy and strong logistics infrastructure must be consistent. While challenges like skills gaps and heritage infrastructure remain, India’s commitment to digitalization, government initiatives like “Made in India”, and increased adoption of automation in areas such as energy, manufacturing and infrastructure indicates strong momentum.