As the sunlit room buzzed with the energy of innovators and industrialists, the stage was set for one of the summit's most eagerly awaited discussions: "Factory 4.0 to 5.0: From Automation to Augmented Intelligence."
Led by Pallab De, Partner and Leader of Operations and Manufacturing Consulting at PwC India, the panel featured a diverse group of speakers. This included Ashok Rajpal, Managing Director of Ambrane India; Ankit Jaipuria, Co-Founder of ZYOD; Rupesh Gandupalli, CEO and Co-Founder of XDLINX Space Labs; Mukesh Sinha, Director of OSEL Devices Limited; Manan Chopra, Director of BENZ Packaging; and Preeti Mishra, Director and Head of Business Development at Holosafe Security Labels Pvt. Ltd. Together, they discussed the transition from smart factories to human-centered, sustainable, and resilient manufacturing ecosystems.
Pallab De began the panel by tracing the origins of Industry 4.0 back to Germany's initiative in 2011 and outlined the three key pillars that characterise Industry 5.0: human-centricity, sustainability, and resilience. To set the context for the discussion, he asked a thought-provoking question: How can Industry 5.0 help India achieve its ambitious target of making manufacturing 25 percent of its GDP by 2030?
Mukesh Sinha, Director at OSEL Devices Limited, acknowledged the challenge and opportunity that lie ahead. "We are currently around 15 per cent contribution from manufacturing. Jumping to 25 percent is a tall order, but not impossible," he remarked. Citing India's favourable position as a China-plus-one alternative, he emphasised the strategic role of schemes like PLI and Make in India. "India is already a software leader. Now, the transition from AI (Artificial Intelligence) to IA (Intelligent Automation) must combine tech with skilled human capital."
He also shared how collaboration has become central to OSEL's strategy. "We recently entered mobile phone manufacturing by partnering with a leading brand. Specialisation and co-creation are the way forward," he said, underlining the importance of building for global compliance and ESG goals.
Ankit Jaipuria, Co-Founder of ZYOD, brought in perspective from the apparel manufacturing sector. "Every 1 per cent increase in manufacturing's GDP share is worth $25 billion. The potential is massive," he pointed out. He spoke about leveraging India's cost-effective labour and improving productivity through AI and IoT. "Industry 5.0 allows us to augment rather than replace humans. From improving labour efficiency to enabling traceability for better margins in international markets — this is transformative," he asserted.
Ashok Rajpal, Managing Director at Ambrane India, took a more philosophical view. "India already has a vast population. Our human intelligence and ingenuity are vast assets," he said. Drawing a parallel with the craftsmanship behind Rolex watches, he noted, "It's the human touch that creates precision and beauty. Factory 5.0 isn't just smarter factories; it's about bringing back human creativity into the production process." His comments resonated with many in the audience; a reminder that technology must complement, not replace, human input.
The Transition Question: Are We Ready?
Pallab then raised a critical issue: Do we need to fully complete Industry 4.0 before transitioning to 5.0? Manan Chopra, Director of BENZ Packaging, responded candidly. "Most industries are still navigating 4.0. At BENZ, we have automated key processes to reduce waste and improve lead times, but 5.0 demands deeper integration with people," he said.
He shared a moving story of a senior operator who feared job loss due to vision AI integration. "We helped him understand that his expertise was vital to train the AI, not be replaced by it. That change in mindset is the essence of Industry 5.0," said Chopra.
He also emphasised that digital transformation must be democratised across the organisation. "It's not just for the tech team. Everyone, including frontline workers, must feel empowered to contribute," he added, recalling how a production worker optimised a scheduling tool in just 30 minutes.
Building Secure, Traceable, and Human-Focused Systems
Preeti Mishra, Director & Head of Business Development at Holosafe Security Labels, added a vital dimension by emphasising on the role of security and traceability in this evolution. "Factory 5.0 also means securing supply chains and creating digitally verifiable products," she said. With increasing global regulations, especially in exports, traceability through smart labelling, blockchain, and tamper-proof technologies become crucial. "This is where Indian manufacturers can lead, combining tradition with secure innovation," she affirmed.
Pioneering with Purpose: Space, Speed and Sustainability
Representing the cutting-edge world of aerospace and electronics, Rupesh Gandupalli, CEO & Co-Founder of XDLINX Space Labs, painted a bold picture. "In space tech, agility, precision, and adaptability aren't optional, they are essential," he said. According to him, Industry 5.0 is about building systems that can learn and adapt faster than legacy machines.
"We are pushing for systems where humans don't just monitor but collaborate with AI. That's the next orbit of growth for India — from satellites to semiconductors," he added, advocating for more R&D-backed manufacturing policies and decentralised innovation hubs.
Is Industry 5.0 an upgraded version of 4.0?
Preeti Mishra, Director & Head of Business Development at Holosafe Security Labels Pvt. Ltd., opened a critical discussion by addressing prevailing misconceptions about Industry 5.0.
"There's a perception that Industry 5.0 is merely an upgraded version of 4.0, one that simply means applying more AI in the system," Mishra explained. "But it's fundamentally about being more human-centric, resilient, and sustainable." According to her, machines are now enablers to help humans make more complex and creative decisions.
She cited Holosafe's proprietary tracing blue tool as an example—an AI-powered platform that flags issues in the supply chain such as label misalignments but leaves the final call to human workers. "It empowers our workforce rather than replaces them," she noted. Mishra stressed that transformation doesn't come from technology alone but also from investing in training. "Set your business goals first and then adopt tech to meet them," she advised.
Adding to the point, Pallab De emphasised the importance of traceability in sectors like automotive. "With AI, you can reduce errors and manufacturing waste significantly," he said. "But it must be paired with the change in the management and employee training to deliver real results."
Emphasis on R&D and Innovation
Turning the spotlight to R&D and innovation, Mukesh Sinha, Director, OSEL Devices Limited, pointed out that India's R&D investment is a mere 0.07 per cent of GDP compared to over 2 per cent in developed nations. "To build a truly global manufacturing ecosystem, collaboration between industry and institutions is essential," said Sinha. OSEL has partnered with IMI to develop coursework on AI in healthcare and has established an industry-shared testing lab to spur innovation.
Ankit Jaipuria, Co-Founder, ZYOD, shared how digital design tools and virtual sampling are revolutionising product development. "By using 3D mockups, we cut sampling time from 100 days to under 20," he said. "This frees our engineers to focus on innovation and helps reduce wastage with real-time feedback loops."
In response to how automation is changing production planning, Jaipuria added, "Earlier, line optimisation was manual and reactive. Now, basic AI solvers can restructure production flows in real-time, saving man-hours and enhancing efficiency."
Preeti Mishra returned to the discussion to speak about how augmented intelligence supports mass customisation. "Tools like additive manufacturing make it cheaper to prototype," she said. "Combine that with customer data analytics, and you get a responsive manufacturing setup that adapts quickly to individual needs."
Navigating Challenges
On the critical subject of cybersecurity, Rupesh Gandupalli, CEO & Co-Founder, XDLINX Space Labs, warned that space-based systems are increasingly vulnerable. "Satellites are now software-defined and highly miniaturised, making them prime targets for cyber-attacks," he cautioned. "We are adopting zero-trust architecture and layered authentication to safeguard assets both in orbit and on the ground."
Gandupalli elaborated on the role of digital twins in the space sector. "In space, there's no concept of a product recall," he explained. "We create virtual models of satellites from the design stage and continue to update them post-launch, allowing us to pre-emptively identify and resolve anomalies."
Bringing in a note of caution, Ashok Rajpal, Managing Director, Ambrane India, reflected on the potential downsides of over-automation. "Machines bring precision and speed, but innovation still requires people," he remarked. "Industry 5.0 is about striking the right balance between man and machine." He added that leveraging India's large talent pool can improve product quality and foster global competitiveness.
Conclusion
In closing remarks on change management, Mukesh Sinha shared OSEL's journey from SME to IPO. "With greater public accountability, we had to align purpose, product, people, and performance," he said. "Change must start with clear intent and be backed by continuous training."
Manan Chopra, Director, BENZ Packaging, echoed similar sentiments. "We are scaling quickly, and that means formalising process control and blending youthful energy with senior expertise," he said.
Rajpal highlighted the strategic importance of global exposure. "We have sent our teams abroad to better understand quality standards and tech implementation," he said. "Regular training ensures our people are not just part of the process but lead it."
The panel concluded with a unanimous belief that Industry 5.0 is not about replacing people with machines but about empowering them through technology. Human-centric innovation, backed by data and driven by purpose, is the way forward for Indian manufacturing.
