Introducing Brain–Computer Interfaces in Factories and Fabrication Lines for the Inclusion of Disabled Workers–Industry 5.0—A Modern Challenge and Opportunity

Abstract

Flexible factories and adaptive fabrication lines offer a testbed for advanced multimodal interaction concepts that can support the inclusion of disabled workers in Industry 5.0 manufacturing systems. The study synthesizes interdisciplinary data from ergonomics, industrial automation, and EU regulatory frameworks to establish a conceptual model for human-machine interaction. Building on conceptual modeling and a structured literature analysis, the study proposes a six-step integration framework that links task demands, worker capabilities, and interaction modalities within human-in-the-loop manufacturing environments. Although no empirical case study was conducted in this phase, an exemplary application is presented for a semi-automated bike wheel manufacturing process. Detailed machine-based assembly line flows and simulated process data were utilized for illustrative purposes to depict the process and validate the proposed Capability–Task Matching Matrix. The results operationalize the human-centric vision of Industry 5.0 by providing a structured methodology for the inclusion of disabled workers within fabrication environments. The findings are organized into two primary components: the conceptual development of the Integration Approach and its practical application to a semi-automated industrial use-case. Finally, a particular focus is placed on Brain–Computer Interfaces (BCIs) as an emerging interaction channel that enables non-muscular control, attention monitoring, and neuroadaptive feedback, complementing conventional interfaces rather than replacing them. The framework is illustrated through application to the same semi-automated bicycle wheel assembly line, where BCI-supported interaction, augmented interfaces, and robotic assistance are mapped to specific production tasks and assessed in terms of feasibility and technological maturity. Drawing on the paper’s results, an explanatory 10-year roadmap outlines the feasibility and phased deployment of BCI solutions. It aligns technological advances with European regulations and a vision for a fully inclusive manufacturing enterprise.