Journal Pre-proofs

A Human Cyber Physical System Framework for Operator 4.0 – Artificial In‐
telligence Symbiosis

Alexandros Bousdekis, Dimitris Apostolou, Gregoris Mentzas

PII: S2213-8463(20)30127-9
DOI: https://doi.org/10.1016/j.mfglet.2020.06.001
Reference: MFGLET 258

To appear in: Manufacturing Letters

Received Date: 27 January 2020

Revised Date: 5 May 2020
Accepted Date: 5 June 2020

Please cite this article as: A. Bousdekis, D. Apostolou, G. Mentzas, A Human Cyber Physical System Framework
for Operator 4.0 – Artificial Intelligence Symbiosis, Manufacturing Letters (2020), doi: https://doi.org/10.1016/
j.mfglet.2020.06.001

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 A Human Cyber Physical System Framework for Operator 4.0 – Artificial
Intelligence Symbiosis

Abstract: The emergence of Artificial Intelligence (AI) reveals new opportunities in Industry 4.0
environments. However, the lack of appropriate data and the requirements for trustworthiness pose
significant challenges in the applicability and the effectiveness of AI systems in manufacturing
environments. On the other hand, Industry 4.0 enables new types of interactions between humans and AI,
but also between digital and physical worlds in the context of Cyber Physical Systems (CPS). In this paper, a
Human Cyber Physical System (HCPS) framework for Operator 4.0 – Artificial Intelligence Symbiosis is
proposed and its main architectural building blocks are described.

Keywords: Industry 4.0, Digital Twin, Asset Administration Shell, Explainable AI, Human-Machine Symbiosis,
CPS, smart manufacturing.

1 Introduction

Sixty years after Licklider’s seminal paper entitled “Man-Machine Symbiosis” (Licklider, 1960), recent
advances in Artificial Intelligence (AI) and Cyber Physical Systems (CPS) make this aspect remaining a core
challenge. Human-machine symbiosis in the AI era, and especially in Industry 4.0 environments, is at its
early stages and there are still many unexplored opportunities (Abbass et al., 2018). Industry 4.0 enables
new types of interactions between operators and machines (Rauch et al., 2020; Fantini et al., 2020). This
allows a paradigm shift from independent automated and human decisions towards a human-AI symbiosis,
characterized by the collaboration of AI and human intelligence (Romero et al., 2016; Guerin et al., 2019). ).
In this paper, a Human Cyber Physical System (HCPS) framework for Operator 4.0 – AI Symbiosis is
proposed and its main architectural building blocks are described. Operator 4.0 is the “operator of the
future”, a smart and skilled operator who performs “work aided” by machines if and as needed in an
Industry 4.0 environment (Romero et al., 2016). The HCPS concept, building on top of human-automation
interaction (Hancock et al., 2013), aims at studying the symbiosis between humans and AI, having the
human as an integral part of the CPS.

In recent years, human – machine symbiosis in the Industry 4.0 era has started to emerge, however still at a
conceptual level. Fletcher et al. (2020) identified the key requirements to form a design framework for
future human-automation assembly system, while Kaasinen et al. (2020) analyzed user expectations and
concerns related to the Operator 4.0 in order to derive design implications for empowering and engaging
Operator 4.0 solutions. On the other hand, Emmanouilidis et al. (2019) proposed a viewpoint for enabling
human in the loop engagement linked to cognitive capabilities. The authors highlighted the role of context
information management in industrial systems and particularly in the joint management of linked
maintenance data and knowledge and IoT-driven analytics for product lifecycle management. Romero et
al. (2015) proposed a human-centered architecture in the context of adaptive automation to increase
operators’ working capabilities. Romero et al. (2017) proposed a more generic and holistic architecture. In
their work, the symbiosis is realized with the interaction of interface and broker agents in the context of a
multi-agent architecture for the social factory. Zhou et al. (2019) concluded in the technical implications
and major challenges for the adoption of HCPS in the context of intelligent manufacturing. Particularly for
the human-machine symbiosis, these include the effective cooperation between humans and machines and
the ethical issues introduced by AI.

The aim our framework is to facilitate non-disruptive and non-intrusive Operator 4.0 decision
augmentation, while facilitating real-life feedback from the shopfloor. The final decision is taken by the
human as the main actor taking the responsibility of the action. Our framework moves beyond the state-of-
the-art in two main directions: (i) It foresees a Digital Twin-driven symbiosis between AI-enabled
manufacturing systems and operators. To this end, apart from an Asset Administration Shell (AAS) for the
implementation of the manufacturing Digital Twin, it incorporates a Human Digital Twin. The latter reflects
and anticipates the human interaction, as well as the operator’s skills, preferences and expectations by
analyzing contextual past behaviours and by creating operator’s digital replica/twin, looking inside-out. (ii)
The framework foresees the utilization of trustworthy and ethical AI as a prerequisite for an efficient
symbiosis, aiming at building the appropriate level of trust for technical robustness and accountability. For
this reason, explainability and interpretability are core aspects during the execution of AI algorithms,
especially when the generated insights are against operator’s experience.

2 Pillars of the Human Cyber Physical System Framework

The proposed HCPS framework is based upon 3 pillars, as shown in Figure 1: AI in manufacturing, Digital
Twins in CPS and Operator 4.0-AI symbiosis. Table 1 describes the challenges related to each pillar.

Figure 1: The 3 pillars of HCPS framework

 Table 1: Challenges related to the HCPS Pillars
Pillar Challenges
AI in Comparing to other domains, the manufacturing environment has additional challenges
Manufacturing to the application of (deep) machine learning algorithms: (i) the scarcity of events; (ii)
the partially observable environment; (iii) the low quality, quantity and suitability of the
collected training data; (iv) the capital-intensive and critical processes; and, (v) the
inconvenience of the personnel to intrusive changes in their work. Therefore, data
should be combined with knowledge in order to result in effective learning systems
(Amershi et al., 2014). However, the operator’s expertise, cognition, perception but
also past experiences is not usually recorded, although this is what usually guides their
work.
Digital Twins in Digital twins implement the AAS for facilitating interoperability in Industry 4.0 (Ye, and
CPS Hong, 2019). They are key enablers of CPS, which renders physical objects accessible as
services on a virtual network, since they unlock the application of advanced forms of AI
in manufacturing operations (Alam, and El Saddik, 2017; Leng et al., 2019). Their full
potential is exploited when they support all the three types of communication: (i)
between the physical and the virtual twin; (ii) between different Digital Twins; (iii)
between the Digital Twins and domain experts.
Operator 4.0 – While completely autonomous AI systems are important in some application domains
AI Symbiosis where the human is not physically present (e.g. underwater or deep space exploration),
many application areas are addressed most effectively and reliably by a combination of
humans and AI systems. Nowadays, AI algorithms take increasingly complex decisions,
but humans have to bear the risk of inappropriate decisions that may have significant
implications. Operator 4.0-AI symbiosis is a key factor towards social sustainability of
Industry 4.0 (Romero et al., 2020), since AI’s larger impact will be in complementing
and augmenting human capabilities (IEEE Standards Association, 2019; Zolotová et al.,
2020). Humans and AI should work together exploiting and enhancing each other’s
complementary strengths: the leadership, teamwork, creativity, and social skills of the
former, and the speed, scalability, and quantitative capabilities of the latter (Wilson,
and Daugherty, 2018; Grigsby, 2018; Rabelo et al., 2018; Barricelli et al., 2019). In this
way, Operator 4.0 and AI will achieve shared trust and expectations with minimum
communication overhead.
3 Human Cyber Physical System Framework for Operator 4.0 – AI Symbiosis

The HCPS framework depicted in Figure 2 consists of the Physical, the Cyber and the Human world. The
Physical World deals with the products and processes equipped with smart sensors. The Human World
deals with Operator 4.0 and includes two bidirectional collaborative interaction channels: “AI Assisting
Humans” and “Humans Assisting AI”. The Cyber World consists of 3 building blocks: Integrated Product &
Process Digital Twin, Human Digital Twin, and Operator 4.0-AI Interaction & Symbiotic Planning.

Figure 2: The HCPS framework for Operator 4.0-AI symbiosis

The Integrated Product & Process Digital Twin implements the I4.0 Asset Administration Shell (AAS),
allowing the integration of the digital twin and its physical counterpart into Industry 4.0 communication,
providing a controlled access to all information, and modelling information for generating services and
functions related to the asset. It mainly constitutes the “voice of data” about manufacturing operations. It
is based upon the Integrated Product & Process Development concept (Heimann, and Westfechtel, 2019)
which dictates the simultaneous optimization of the product and its manufacturing to meet cost and
performance objectives. Based upon the AAS template proposed by Ye and Hong (2019), the AAS of the
Integrated Product & Process Digital Twin consists of generic and asset-specific sub-models, as depicted in
Figure 3. The level of granularity of the asset-specific sub-models may vary, e.g. by having one asset-specific
sub-model for each operation.

Figure 3: The I4.0 AAS of the Integrated Product & Process Digital Twin
Data Ingestion obtains and imports the required product- and process-related data to the AAS for. It
establishes the basis for seamless integration of data and connection of the Physical World with the
Integrated Product and Process Digital Twin of the Cyber World. It includes data pre-processing techniques
(e.g. unbiased and representative input data, automatic methods for data verification, data cleaning,
parsing and assembling) in order to acquire: (i) data-in-motion, i.e. high-dimensional and high-frequency
data from the equipment-installed sensors, through an Industrial IoT gateway (implementing e.g. OPC-UA,
AutomationML, MQTT, AQMP, etc.); (ii) data-at-rest, i.e. business and historical data, from enterprise
systems in a configurable and standard way; and, (iii) machine identification data (e.g. manuals, machine
identity, etc.).
Data-driven AI Algorithms cover the whole information lifecycle (descriptive, predictive and prescriptive
analytics) for providing insights. This component incorporates (deep) machine learning algorithms for
building offline analytics models and then, using them in order to perform real-time data processing.
Indicative methods include: Time-series classification and clustering, Bayesian Networks, Hidden Markov
Model (HMM), Deep Convolutional Neural Network, Long Short-Term Memory (LSTM) Recurrent Neural
Network, etc.
Process & Product Simulation facilitates the digital representation and anticipation of the physical assets
and their behaviors for various structural changes and what-if scenarios. Generative design approaches (Oh
et al., 2019) can be used in the interface between product and process in order to analyze the balance
between requirements and limitations.
The execution and interaction of the Data-driven AI Algorithms and Process & Product Simulation result in
Reasoning for Process Optimization, in order to facilitate decisions by computationally determining a set of
high-value alternative actions or decisions given a complex set of objectives, requirements, and constraints.
Process Optimization executes, among others, (i) Detections of abnormal situations; (ii) Predictions of
future states; and (iii) Proactive Optimization. The outcomes are subject to Interpretation for evaluating the
performance and defining the level of trust.
The Human Digital Twin mainly constitutes the “voice of experts”. It reflects and anticipates the human
interaction, the worker’s skills, preferences and expectations as well as the manufacturing environment’s
constraints and requirements achieved by analyzing past behaviours. Knowledge Acquisition obtains and
imports the required product- and process-related knowledge. It acquires Operator 4.0 knowledge, both at
design time and through real-life feedback from the shop-floor. It establishes the basis for seamless
incorporation of knowledge from the Human World into the Cyber World.
Knowledge-driven AI Algorithms aim at providing insights by taking advantage of the contextual expert
knowledge, cognition and perception as well as real-life feedback from the shop-floor. In this way, they
implement algorithms for analyzing past behaviours, identifying best practices and adapting them to
emerging circumstances and novice, less-experienced operators, simulating and reasoning about possible
future interactions. Therefore, they exploit the collective knowledge of a community of experts (a pool of
up-to-date contextual knowledge) for proactively supporting the Operator 4.0. Knowledge-driven AI
algorithms aim at overcoming the computational costs and the large amount of training data required by
deep learning algorithms by executing the human-like ability of transferring and reusing knowledge across
tasks. To do this, it will exploit methods such as Case-Based Reasoning and Transfer Learning, in order to
store knowledge gained while solving different but related problems.
Knowledge Representation & Management supports reuse of integrated and continuous knowledge and
its representation in standardized format. It extracts the structure and organize the knowledge from
various sources of human experts. It includes methods for knowledge modelling that facilitate generating
domain-related knowledge representations in terms of objects, events, performance, meta-knowledge and
facts.
The execution and interaction of the Knowledge-driven AI Algorithms and Knowledge Representation &
Management result in Reasoning for Operator 4.0 Support in order to reflect the operator’s skills and
preferences as well as the manufacturing environment’s constraints and requirements. Therefore, Non-
disruptive Predictive Operator 4.0 Support enables the Human Digital Twin to serve as: (i) Personal
Assistant, without requiring any disruptive and intrusive changes in people’s work, by predicting how the
Operator 4.0 will respond to an issue instead of recommending the optimal solution derived from data
analytics models; (ii) Personal Monitor, in the sense that it notices if the Operator 4.0 makes a choice that is
inconsistent with previous choices or in the given context so that they correct their decision, if that was not
done on purpose, or make AI learn on updated business procedures; (iii) Personal Coach, providing a
feedback loop that allows users to look at their own performance understand their decision patterns and
reflect on variations and errors. The outcomes of the Human Digital Twin are subject to Interpretation.
Operator 4.0-AI Interaction & Symbiotic Planning is responsible for the optimized Operator 4.0-AI
decisions and the establishment of their symbiosis by combining “big data” from the Integrated Product &
Process Digital Twin and “big knowledge” from the Human Digital Twin. It enables a continuous and
autonomous improvement of the symbiosis in order to create tightly coupled partnerships. Digital Twin-
driven Human-Machine Interaction provides context information and formal representation of the
Operator 4.0-AI interaction in order to achieve shared situation awareness throughout the whole
information lifecycle in the Digital Twins. In this way, the HCPS predicts and augments the performance of
the user and the human supports and enhances the performance of AI. It serves as the means for
exchanging data, information, knowledge and models between the two aforementioned Digital Twins so
that both of them are aware of the changes in each other’s intelligence. In other words, it combines and
processes the engineered knowledge (“voice of experts”) and the learned knowledge (“voice of data”) of AI
algorithms aiming at making the HCPS capable of learning from fewer past experiences, while it assures
their consistent continuous adaptation. However even in this way, their outcomes may be at different
levels of abstraction or even contradictory, as a result of their different objectives (process optimization
and non-intrusive support, respectively).
This challenge can be tackled with the Fusion of Digital Twins Recommendations, which incorporates
methods for fusing the recommendations provided by the Digital Twins and ensuring scalability and
reusability of their outcomes by using all the available sources of information. It also assures that the
outcomes of the Digital Twins are legible for humans and are compliant to given specifications. It is able to
deal with uncertainty caused by, on the one hand, the models and incomplete data, and, on the other
hand, the different level of abstraction and the potentially contradictory insights derived from the Digital
Twins. This moves far beyond the mere correlation of data from different sources, since it needs to take
into account the analysis which led to these specific results as well as their interpretation.
Adaptive and Symbiotic Planning provides proactive assistance and decision augmentation in an adaptive,
dynamic and non-disruptive manner taking into account multiple objectives. It defines the optimal balance
between human and AI (short- and long-term) decisions in order to facilitate sustainable joint decision
making. This balance depends on the availability and suitability of data, Operator 4.0’s trust to the AI
system, skills, preferences and past experiences in similar situations. Hence, it facilitates sustainable
decisions from fully automatic to pure manual making it possible to rely on humans and AI to jointly
achieve the manufacturing objectives. To do this, it will implement methods such as Reinforcement
Learning (RL) in order to maximize the notion of cumulative reward, i.e. rewarding desired behaviours
and/or punishing undesired ones. RL is able to incorporate model-free adaptive algorithms that do not
require a-priori models (Dornheim et al., 2019), something which is beneficial for the multi-factor
environment of the Operator 4.0-AI symbiosis. Therefore, the decisions will be allocated on the basis of the
Digital Twin-driven Human-Machine Interaction and the Fusion of Digital Twins Recommendations. The
final decision is taken by the Operator 4.0 and their feedback updates the models and algorithms of the
framework. Explanation of Results provides explainability and transparency in order to inspire confidence
that the system is secure, robust, controllable and private, especially when it recommends different actions
than the ones that Operator 4.0 intended to perform. Explainability (Li et al., 2020) provides the means to
support human-AI symbiosis ecosystem and effectively manage the emerging generation of artificially
intelligent partners, offering explainable value through automated reasoning aiming at assisting and
facilitating the work of the Operator 4.0.

4 Conclusions and Future Work

This paper presents a HCPS for Operator 4.0-AI symbiosis in Industry 4.0 manufacturing systems. It presents
a conceptual architecture for making humans, cyber systems, and physical systems working together in
optimal complementarity by taking advantage of the strengths of both human intelligence and machine
intelligence. The proposed framework will serve as a blueprint of our future work aiming at developing a
HCPS for Operator 4.0-AI symbiosis in compliance with the Industry 4.0 principles. Up to now, there are
mainly conceptual approaches on human-machine symbiosis, while others focus on specific manufacturing
processes (see e.g., Romero et al., 2017; Guerin et al., 2019; Kaasinen et al., 2019; Emmanouilidis et al.,
2019; Fletcher et al., 2019).

The proposed framework is planned to be implemented in three industrial use cases: (i) agile production
planning for high-precision machining of parts with complex geometries for wind turbines; (ii) AI-driven
resource planning based on individual human skills development in assembly of electronics mobility
components; and, (iii) predictive quality improvements for welding and painting automotive body shop
processes. The performance and the effectiveness of the adaptive and evolutionary symbiosis will be
evaluated in two directions: (a) directly, by measuring the operator’s average long-term productivity boost,
the number of interactions per day between Operator and the AI, the percentage of the AI-generated
actions accepted by the operator per day, and the reduction of non-compliances due to operator errors;
and (b) indirectly, with KPIs related to agility and improved product and process quality, i.e. measuring the
Overall Equipment Effectiveness (OEE), the reduction of downtime, the just-in-time processes, the
reduction of operating costs, the timely reconfiguration, the reduction of reworks of scrapped parts, and
the reduction of products returns.

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