Operator 4.0 solutions

The Operator 4.0 laboratory at the University of Pannonia in Hungary demonstrates how a company can develop and apply the enabling technologies of Industry 4.0 to make a human-centered working space. Behind the MTA - PE Lendulet Complex Systems Monitoring Research Lab, we call for research and industrial partners to a human-centric shop floor solution to make worthwhile production from the economic and human sides. We have the obligation and the excellent opportunity to shape these changes and challenges. For that, we are organising the Operator 4.0 community.

Virtual Operator*

We are using the HP Reverb VR3000 G2 VR headset to improve operator efficiency. The VR technology help to optimize the decision-making process for smarter operators. Thanks to that technology, a combination of interactive virtual reality and advanced simulations of realistic scenarios is provided.

Healthy Operator*

Polar OH 1 wearable sensor is used to get precise heart rate from the operator during production. Our research focuses on integrating this monitored data (physical workload - exercise activity and cognitive workload - mental effort during the work-shift) data with indoor positioning information. The health-related metrics can be used to plan and schedule the work shifts, rest breaks, and operator overtime.


To further maintain the healthy status of workers, digital biomarkers are used to detect their strengths and mental limitation, thus the work content (workload, work pace, etc.) can be adjusted accordingly. In our approach, the Polar OH1 wearable sensor is deployed to monitor the heart rate of the operator during his production shift. By analyzing the Heart Rate Variability, his physiological changes can be under close observation. The aim is to design the physical workload (production activity) and cognitive workload (mental effort) to personally suit the ability of the worker.

In combination with data from the indoor positioning system, customized service can be brought to the place where the worker is in a timely manner. Better allocation of production resources can also be made, that fits to his personal work plan (such as work shifts, rest breaks, overtime).

Collaborative Operator*

CoBots (Collaborative Robots) relives tedious, non-ergonomic and vulnerable tasks from operators. We applied a UR3 Collaborative Robot arm to support the operator during the assembly process. Based on the Intelligent Space, we could predict better co-working interaction to improve the smart operator productivity.

Analytical Operator*

A Digital Twin is developed based on the Siemens Tecnomatix Plant Simulation platform to discover helpful information and predict relevant events for continuous improvement and provide greater visibility of KPIs and real-time alerts based on predictive analytics. The Real-time Locating System is used to get location and other sensor-based information in real-time based on the Intelligent Space concept.

Digital model of the Operator

We aim to create models about the operators on the shop floor, using semantic technologies such as ontologies or knowledge graphs. We also utilise the operator activity or skill-related industrial standards and description methods such as ISA-95, B2MML, or AutomationML. A model that accurately describes the operator can facilitate the design of human-machine collaboration and a more ergonomic or safe work environment.

The development trend of system integration in the manufacturing industry is to achieve standardization. ISA-95 is one of the essential standards in enterprise-control system integration and serves as a highly utilised basis for design Industry 4.0. The Personnel model contains information about the Class type of person in the enterprise, such as a production manager or operator; the Property as seniority, position, or division; and Qualification such as a particular task or position of the Personnel.

The Operator 4.0 solutions are based on Prof. Dr David Romero et al., who first defined the Operator 4.0 paradigm. Their project is "The Operator 4.0 - Towards Socially Sustainable Factories of the Future", which is the basics of all of the further researches and applications besides this topic.

* Romero, David, et al. "Towards an operator 4.0 typology: a human-centric perspective on the fourth industrial revolution technologies." proceedings of the international conference on computers and industrial engineering (CIE46), Tianjin, China. 2016. - https://bit.ly/3pOi3gm