Impact of Industry 4.

0 on Occupational
Health and Safety

Aleksandra Polak-Sopinska(&), Zbigniew Wisniewski,

Anna Walaszczyk, Anna Maczewska, and Piotr Sopinski

Faculty of Management and Production Engineering,

Lodz University of Technology, Wolczanska 215, 90-924 Lodz, Poland
{aleksandra.polak-sopinska,zbigniew.wisniewski,
anna.walaszczyk,anna.maczewska}@p.lodz.pl,
piotrsopinski@onet.eu

Abstract. Background: The objective of Industry 4.0 is to bring into existence

smart, self-regulating and interconnected industrial value creation through the
integration of cyber-physical systems into manufacturing. Industry 4.0 is a new
paradigm of production and one that leads to a faster and more precise decision-
making, entirely new approach to production, work organization manner of
work task performance, which may have a significant influence on the health
and safety of workers. Objectives: To provide an overview of potential effects
(positive and negative) of Industry 4.0 on occupational health and safety and to
list some of the recommendations regarding the integration of OHS into man-
ufacturing in the Industry 4.0 context. Methods: A critical review of the liter-
ature currently available on this topic. Results: There are many risks as well as
opportunities for occupational health and safety that derive from Industry 4.0.
A considerable challenge, especially in the transitional period, is posed by
insufficiency of initiatives with respect to occupational health and safety
including standards and regulations, which may render them incommensurate in
the face of newer and newer threats as Industry 4.0 technologies emerge. Fur-
thermore, it may lead to forfeiting the proactive approach towards occupational
health and safety that has been established in the most industrialized countries.
Further research is required to enhance integration of occupational health and
safety into manufacturing in the context of Industry 4.0. To achieve this, an
interdisciplinary approach needs to be adopted drawing on the expertise of a
team comprising engineers, IT experts, psychologists, ergonomists, social and
occupational scientists, medical practitioners, and designers. The overview was
carried by the research group IDEAT.

Keywords: Occupational health and safety
Occupational risk

Occupational hazards
Organization of work
Management

Industry 4.0
Smart technologies
Smart factory

© Springer Nature Switzerland AG 2020

W. Karwowski et al. (Eds.): AHFE 2019, AISC 971, pp. 40–52, 2020.
https://doi.org/10.1007/978-3-030-20494-5_4
 Impact of Industry 4.0 on Occupational Health and Safety 41

1 Introduction

The wave of digitalization that dates back to the era of the third industrial revolution
has prepared the way for Industry 4.0. The term ‘Industry 4.0’ was first used in 2011. It
is derived from an initiative launched by the German government for safeguarding the
long-term competitiveness of the manufacturing industry [1]. By integrating cyber-
physical systems (CPS) into manufacturing, Industry 4.0 is to bring into being smart,
self-regulating, and interconnected industrial value creation. CPS includes inteeligent
machines, storage systems, and production machinery which can exchange informa-
tion, initiate actions and control one another. Their interconnection by way of the
Internet, which has also been designated as the Industrial Internet of Things (IIoT),
generates a technological leap for engineering, production, flow of materials, and
sypply chain management [1].
In many regards, Industry 4.0 is much the same as the previous industrial revo-
lution: compared to the preceding era, what drives Industry 4.0 is the transformation of
the production goods and services by increasing its efficiency [2]. Nevertheless,
Industry 4.0 provides a new paradigm of production that leads to a faster and more
accurate decision-making, an entirely new approach to production [2], work organi-
zation and manner of job task performance, which may have a meaningful influence on
the health and safety of workers. Therefore, the aim of the article is to provide an
overview of potential effects (positive and negative) of Industry 4.0 and its components
on occupational health and safety (OHS) and to list some of the recommendations
regarding the integration of OHS into manufacturing in the Industry 4.0 context.

2 The Concept of Industry 4.0

The idea of Industry 4.0 represents the 4th industrial revolution in which cyberphysical
systems play a primary role. CPS are defined as the connections between and coor-
dination of computational and physical resources. It should be understood that
computer-based algorithms control and manage many aspects of contemporary
industry. CPS enable application of smart solutions in factories and warehouses [3].
Apart from cyberphysical systems, the most important components of Industry 4.0 are
[3, 4]:
– Internet of Things (IoT) – a network of physical devices and applications connected
and exchanging information in real time;
– cloud computing – IT technology enabling ubiquitous access to system resources
and data processing via the Internet;
– edge computing – a method of optimizing cloud computing systems where the data
is processed on the edge of the network, as close to the source as possible;
– Big Data analytics – processing large and varied data sets;
– autonomous production or autonomous assembly – self organizing computer
assisted production planning;
– the IT/OT convergence – increase of the role of IT solutions in the operational area;
– additive manufacturing – 3D printing and fast prototyping;
42 A. Polak-Sopinska et al.

– advanced robots and co-robots (cobots) – collaborative robots physically inter-

acting with workers in production areas;
– augmented reality – system connecting a physical, real-world environment with
computer-generated ones;
– horizontal and vertical integration – a kind of business expansion strategy;
– rapid application development – enabling support of various aspects of human
activities;
– digital twin simulation models – a technology based on digital model of machines
or production systems that enables real-time monitoring and designing new
businesses.
The 4th Industrial Revolution is happening globally and concurrently. In Europe,
Germany (Industrie 4.0), France (the Nouvelle France Industrielle), Sweden (Produktion
2030), Italy (Fabbrica Intelligente), Belgium/Holland (Made Different), Spain (Industria
Conectada 4.0), and Austria (Produktion der Zukunft) are all actively taking an interest
[5]. The EU initiated a public-private partnership under the title Factories of the Future,
designed to ensure sustainable and competitive production. In the U.S., similar ideas are
encouraged through the Industrial Internet Consortium with founding members such as
AT&T, CISCO, GE, IBM, and INTEL. In China, the Internet Plus or Made in China
2025 initiative integrates current technological developments such as cloud computing
and big data to enable state-of-the-art manufacturing. South Korea announced the
Manufacturing Innovation 3.0. In all of these regions as well as in countries such as
Japan and Singapore high investments are anticipated, whereas in Germany they are
expected to exceed two billion Euro annually between 2018 and 2020 [2].
The rate at which technological advances are implemented is increasing yet,
unfortunately, it often is rather erratic due to insufficient preparation of organizations
for the implementation of new technologies [6], which fills us with misgivings as to
whether we are going to forfeit a proactive character of OHS action. Whether we are
going to miss the moment when preventive actions become primarily corrective again
due to insufficient knowledge, skills, and competences prerequisite for predicting risks
brought about by Industry 4.0 technologies. Importantly, in the recent years, the most
industrialized countries have managed to develop a proactive approach to OHS.
Industrial business has started to comprehend that the health and safety of workers is
one of the paramount elements in the financial success of the enterprise, which is why it
is so meaningful to know and understand the threats and opportunities that Industry 4.0
and its component parts bring about for OHS.

3 Research Method

In order to provide an overview of potential effects (positive and negative) of Industry

4.0 and its components on occupational health and safety and to list some recom-
mendations regarding the integration of OHS into manufacturing in the context of
Industry 4.0, a review of the literature was performed with the aid of certain keywords.
First, the combination of the keywords “occupational health and safety” and “Industry
4.0” were combined (or, and). Next, “occupational health and safety” was put together
 Impact of Industry 4.0 on Occupational Health and Safety 43

with (or, and) technological categories related to Industry 4.0 such as “Internet of
things”, “Big data”, “cobotics”, “computer simulations”, “artificial intelligence”,
“augmented reality”. In the third step, the search was expanded to include other terms
associated with OHS and Industry 4.0 such as “occupational health”, “occupational
safety”, “occupational risk”, “work organization”, “workplace organization”, “smart
factory”, “smart technologies”, “smart production”, “smart manufacturing”, “smart
industry”, “advanced manufacturing”. The literature review was conducted in the
period from November 2, 2018 to January 15, 2019. The search was done in three
databases: the Web of Science, Scopus and PubMed. The time range for the search was
defined as 2010 through 2018. Publications of this year were not included due to
continuous changes in their number. All titles and abstracts collected in the computer-
based search were looked at, which allowed the authors to select those articles that
appeared relevant for the purpose of the review according to the inclusion criteria. They
included peer reviewed research papers, review articles, and conference papers. In the
following stage of the review, documents developed by international governmental
agencies which were published in English and dealt with worker health and safety
issues related to Industry 4.0 technologies were included as were articles on the topic
published in Polish.

4 Results

The concept of “Industry 4.0” is now one of the most discussed subjects in manu-
facturing technology circles, business groups, researchers and experts in several fields
[7, 8]. Although there has been an enormous increase in the number of scientific
publications on the subject of Industry 4.0, few of these raise OHS issues in any helpful
way. The authors found 31 publications/documents that meet the inclusion criterion.
All the included publications and documents were critically evaluated in order to point
out the opportunities and benefits but also any concerns and issues deriving from the
application (development) of Industry 4.0 for the OHS.

4.1 Industry 4.0 Opportunities and Benefits for Occupational Health

and Safety
Many of the advances in technology that form the foundations of Industry 4.0 have
already been used in manufacturing however, with Industry 4.0, they are expected to
transform production: isolated, optimized cells will come together as a fully integrated,
automated, and optimized production flow leading to greater efficiency and changing
traditional production relationships among suppliers, producers, and customers—as
well as between the human and the machine [4]. Some companies will be able to set up
‘lights out’ factories where automated robots continue production without light or heat
after staff has gone home. For example, in the Netherlands, Philips produces electric
razors in a ‘dark factory’ with 128 robots and just nine workers who provide quality
and safety assurance [9]. This way the number of workers will be reduced. The
remaining manufacturing jobs will contain more knowledge work as well as more
short-term tasks. The workers increasingly have to monitor the automated equipment,
44 A. Polak-Sopinska et al.

are being integrated in decentralized decision-making, and are participating in engi-

neering activities as part of the end-to-end engineering [10]. This may mean that
workers will be involved in more creative, interesting, value-added activities and will
have the opportunity to leave routine tasks and achieve a grater autonomy and self-
development [11, 12].
It is worth emphasizing that the advancing computerization of industry makes it
possible to create work structures that so far have only functioned in its innovative
sectors. It has been pointed out that the importance of issues such as flexible working
time and remote work will be growing for the manufacturing sector. To a much greater
degree that before will project-based work involving the participation of individuals
from and outside the organization be significant [13]. The potential consequences of the
process of the blurring organizational boundaries, growing flexibility of working time,
and remote work have been evaluated differently in the subject matter literature. Many
researchers [1, 14] underscore the fact that increased working time flexibility should
allow the worker to achieve greater work-life balance. The transformed work envi-
ronment will allow workers to regulate their rhythm of work on their own.
Industry 4.0 may render labour safer and healthier owing to early and ongoing risk
analysis and management based on smart safety technologies, virtual engineering, Big
Data, and the Internet of Things [15]. Wireless sensor networks along with properly
designed and integrated technical support may prevent accidents in autonomous and
smart industrial environments [16].
Machines equipped with technical means of monitoring all parameters that have
any bearing on the process will be more apt to respond appropriately the instant any
dysfunction occurs [17, 18]. They will have more and more self-monitoring capability
as well as the ability to monitor their surroundings and send information to diagnostic
centres that will determine whether or not further intervention is necessary.
According to Gisbert et al. in [19] order to ensure the reliability of these systems,
common technological platforms capable of monitoring the functioning and perfor-
mance of all networks and linking sensors to remote control centres need to be
implemented. These platforms will reduce occupational risks by facilitating the inte-
gration of general surveillance applications, which will be complemented with
appropriate risk management. Gralewicz proposed a new concept of risk management
in what is called intelligent work environment with respect to occupational health and
safety using new technologies and solutions developed for the needs of safety-related
areas of work. The approach to intelligent workplace management he advances relies
on new technologies and solutions for which he sets the following tasks related to
occupational safety: monitoring work environment worker health factors, monitoring
machinery and technologies, monitoring personal protective equipment, warning
workers and facilitating their timely information, facilitating decision-making, virtual
3D simulations. The performance of these tasks should proceed according to the
hierarchy of risk management. This approach to organizational risk management
should enable real-time responses to changes in work environment factors and per-
sonalization of risk assessment for individual worker profiles to include their psy-
chological state, specific work environment factors at play, and location with regard to
machines (including robots and cobots) [20].
 Impact of Industry 4.0 on Occupational Health and Safety 45

There is a large range of personal protective devices that use smart technologies
[17], which can help employees stay safe in dangerous workplace environments where
they may be exposed to extreme noise, heat, toxic gases, chemicals, harmful elements.
Similarly, technologies monitoring worker well-being (e.g. pulse, emotions, activity,
temperature, etc.) can provide real-time alerts that indicate the need to adopt preventive
measures designed to stop hazardous behaviors, restore safety procedures, avoid
injuries, and enable an injured worker to reach for help [18, 21, 22].
Furthermore, self-aware, self-learning, self-healing, self-configurating, self-
protecting machines capable of advanced analysis, fit with advanced programming,
sensors, cameras, will be able to predict potential workplace hazards and manage
unexpected conditions, which will facilitate prevention of worker accidents and injuries
[23].
Digital factories use more and more industrial robots that replace the human in the
performance of various job tasks, especially dangerous [24], monotypical, overstraining the
musculoskeletal system, and excessively physically demanding for ones [23]. One type of
robots that is increasingly popular is the collaborative robot (cobot). Thanks to special
sensors and control methods related to the theory of cognitive machines, these robots
autonomously and actively take cognizance of their surroundings (share the workspace) and
analyze their activity to eliminate non-typical situations – which is indispensable if their
interaction with the human is to be safe. This way productivity, and product quality can be
enhanced and at the same time, occupational health complaints and diseases caused by the
manner of work task performance, injuries and accidents can be prevented [25].
According to the German Federal Institute for Occupational Safety and Health,
musculoskeletal injuries are the reason for 23% of sick leave days in Germany and
cause production loss worth an estimated 17 billion euro annually. The situation is
much the same for other European countries. These disorders are mainly attributable to
physical loads during job tasks requiring lifting and carrying, which leads to muscle,
ligament, bone, and cartilage damage. In some cases, common static aids such as
forklifts and hoisting devices may not be used or are not flexible enough. This is when
exoskeletons may prove useful designed to reduce stress/compression force on the
lower back, shoulders, elbows, and wrists and therefore, protect the user against
injuries to this parts of the musculoskeletal system. They provide support for the body
during the positioning or using tools, handling objects, etc. [26]. The design of
exoskeletons includes micromechanical elements and an ultra-light, ergonomic bearing
system. In the future, the retrofitting of the structure with a sensory data transmission
system is expected, which will enable the introduction of machine learning and arti-
ficial intelligence to the exoskeleton controller [27]. Therefore, these devices can
provide safer and more ergonomic work conditions for the workforce which is
increasingly diverse in terms of age, sex, cultural background, and the level of fitness.
Furthermore, they can improve the quality of life of the disabled and the elderly [28].
In the age of European society aging, support for workers with disabilities will also
be provided by humanoid robots which will be able to accurately interpret human
emotions [29]. They will be able to act as personal assistants or job coaches especially
in the initial stages of employment, which will reduce job related stress levels, shorten
the time required for learning a new task, decrease the number of mistakes made by the
worker, etc.
46 A. Polak-Sopinska et al.

All of the above Industry 4.0 innovations will make the workplace a safer, more
ergonomic, and comfortable environment, owing to which people will work more
productively.

4.2 Concerns and Issues Deriving from the Application of Industry 4.0
Relevant for the Occupational Health and Safety
Generally, organizations are not quite ready for the implementation of Industry 4.0.
Only 20% of the respondents assess themselves as being ready for the application of
new supply models. The level of preparation for blurred lines between industries (17%)
is even lower as is the level of preparation for the implementation of smart and
autonomous technologies (15%). The latter is also connected with poor readiness for
reaping the benefits generated by these technologies. Only 22% of manufacturers have
a good grasp of the way new technologies change their workforce and organizational
structure. Similar percentage share of respondents are aware of the influence new
technologies have on the way goods and services are delivered by them. Only 16% of
manufacturers know how to integrate their own solutions with external infrastructure,
whereas a meager 8% have solid business foundations for the implementation of novel
technologies [6]. Unsatisfactory preparation and readiness to gain from these tech-
nologies may, in the transitional period, lead to a deterioration in the quality of work,
increase in the number of injuries, accidents, and other human errors.
Industry 4.0 production systems steadily grow in complexity, which is particularly
evident in the context of the interplay between job content (variety, complexity, skills,
uncertainty, exposure, etc.), organization (team planning, overtime, rush orders, etc.),
management (duties, communication, roles, relationships, problem solving, etc.), and
other organizational factors (promotions, pay increases, occupational safety, social
value of work, etc.). These interactions give rise to a number of types of workplace
hazards, in particular in the psychosocial category. Engineers and designers of
advanced production systems often fail to notice this type of risk although it may be of
utmost significance for management. Also worth pointing out is the fact that psy-
chosocial hazards have already been recognized as considerably challenging with
respect to OSH legislation and management systems BHP [12].
Workers whose job tasks include monitoring smart machines and robots or par-
taking in decentralized decision-making and complex engineering projects will need to
act more autonomously, have excellent communication and digital skills, and an ability
to organize their own work and bear greater responsibility. Unfortunately, many
research findings show [6, 30] that there is a shortage of qualified staff and low level of
digital culture especially among the aging workforce and people with disabilities. For
this reason, workers will need to be more motivated and open to change. They will
have to exhibit greater flexibility in order to cooperate more effectively and will have to
embrace lifelong learning [31]. The importance of lifelong learning is growing in
particular in Western Europe where there is a negative birth rate and where a majority
of the economically active population is growing old. That is why workforce shortage
is increasingly conspicuous for any job, which may lead to excessive fatigue, sickness
absences, increased number of accidents.
 Impact of Industry 4.0 on Occupational Health and Safety 47

Information and communications technologies (ICT) whose importance is ever

increasing in Industry 4.0 widen the competency gap and extend the distance between
young workers who have just recently obtained their qualifications and mature workers
who exited the system of education a significant time ago [32]. Due to a decreasing
share of physical labor in manufacturing and an increasing share of intellectual work,
low-wage workers who are not provided with additional training will be at risk of
losing their job [33], which appears to be unacceptable from a socially-inclusive
occupational perspective [34].
Worker well-being monitoring technologies raise many concerns and can be per-
ceived as an invasion of privacy which is usually experienced as a stressor. Since their use
is reasonably justified, the implementation of worker well-being monitoring technologies
should provide the worker with full control of her/his data. The worker should be able to
choose which information is to be monitored, which could reduce the sense of having
his/her privacy violated. Nevertheless, the disturbing fact is that many people may not be
fully aware of how their data may be used, what it reveals about them, and whether it can
be further circulated. The employer may try to persuade employees to disclose more
information. However, information needs to be placed in a context (e.g., the worker’s
personal circumstances) before it can be properly analyzed. Most likely, this will require
at least some human intervention as context is very hard to grasp and interpret. In any case,
the employer will need to have been trained because the employer will bear the respon-
sibility for actions taken based on this information [22].
The most severe constraint on machine learning is that artificial intelligence is
devoid of contextual self-awareness (therefore, it is useless to expect it to understand
the meaning of reality) – it merely recognizes frequent scripts but only a human/an
operator can know their meaning. For non-standard events (unique) that do not match
any previous scripts, it will not be able to appraise the situation effectively, in which
case its behavior would be difficult to predict [27]. Innovative technologies can gen-
erate new mechanical, electrical, thermal, chemical, and other hazards. Furthermore,
they can lead to new types of accidents due to incommensurate guidelines/regulations/
standards concerning their proper design as well as application. However, technolog-
ical solutions quickly become obsolete, which does not conduce to the development of
standards. Once again, regulatory framework and standards will not be ready on time to
safeguard all workers against the consequences of the implementation of new manu-
facturing systems based on autonomous, smart, interconnected machines [35].
Vigorous increase in the number of devices with Internet connectivity as well as
widespread exchange and processing of data over the Internet network entails a
growing threat of a potential cyber attack which could pose a risk to the health and
safety of workers.
48 A. Polak-Sopinska et al.

5 Recommendations Regarding the Integration of OHS

into Manufacturing in the Industry 4.0 Context

The review of the literature has shown that one of the potential effects (positive and
negative) of Industry 4.0 and its components on occupational health and safety could
be, especially in the transitional period, insufficiency of OHS initiatives including
standards and statutory regulations, which could render them incommensurate in the
face of newer and newer threats as Industry 4.0 technologies emerge. Furthermore, it
may lead to forfeiting the proactive approach to OHS that has been established in the
most industrialized countries. To maintain or improve the level of OHS in manufac-
turing in the context of Industry 4.0, the following recommendations have been made:
– Further research is required to improve the integration of human work and smart
solutions. Design and configuration of intelligent machines still need to concentrate
on physical, social, mental, and cognitive capabilities of the human being. An
interdisciplinary approach to these issues should be adopted drawing on the
expertise of teams comprising engineers, IT experts, psychologists, ergonomists,
social and occupational scientists, medical practitioners, and designers [1].
– Further studies on psychosocial risks brought about by the new model of work
organization are required.
– There is a need to continue research on collaborative robots in order to ensure a
higher level of safety and accommodate physical and cognitive ability of the
worker.
– New international standards should be developed or existing ones should be revised
to protect workers against any and all potential physical and psychosocial risks
arising from novel technologies.
– It is imperative that appropriate strategies of organizational management be
established and implemented that take into consideration the protection of the
worker [36].
– Cooperation with trade unions is recommended as is collective bargaining [2] with
respect to the replacement of humans with robots, artificial intelligence, imple-
mentation of technologies for ongoing monitoring of worker well-being and
performance.
– It is recommended that researchers, experts on advanced technologies of Industry
4.0, OSH specialists, HR specialists, and industrialists collaborate on the imple-
mentation of solution based on an all-encompassing vision of change management
to ensure smooth and safe transition to the new paradigm [12].
– Adoption of socio-technical approach to the implementation of Industry 4.0 solu-
tions is recommended so that technical innovation, models of work organization
and professional development could be closely coordinated with economic and
social circumstances.
– Proactive approach towards risk assessment already at the stage of design or in the
early stages of the implementation of Industry 4.0 innovation be adopted, which
should be feasible if simulation tools based on workplace virtualization are utilized
in the design phase, whereas augmented reality techniques in the stage of prototype
verification. Risk assessment that focuses on the identification of threats in the
 Impact of Industry 4.0 on Occupational Health and Safety 49

initial stages of the manufacturing process should consider, among others, data
management process, maintenance process, manufacturing technologies in use,
machines, tools and materials, human error, physical and psychological load on the
worker [37].
– Further research on the infallibility of personal protective devices that use smart
technologies and devices for ongoing monitoring of the worker well-being is
requisite.
– OHS specialists should be provided with opportunities for continual professional
development, e.g. advanced training on novel technologies and effects of Industry
4.0 on workplace safety.
– Lifelong learning and continual professional development should be promoted.
– Virtual reality and augmented reality tools should be utilized during worker
occupational health and safety training.
– Good practice platform should be provided showcasing examples of integrating
OHS into manufacturing in the Industry 4.0 context. One example of such platform
is “ Plattform Industrie 4.0” created by the German Federal Ministry of Economic
Affairs and Energy and the Federal Ministry of Education and Research [38].
– Measures safeguarding against unauthorized access to enterprise data and infor-
mation used over the Internet. Protection against cyber threats is provided primarily
through security systems (data encryption) and enterprise security architecture.

6 Summary

The review of the literature has revealed many opportunities for as well as many threats
to occupational safety and health deriving from the application of Industry 4.0. A major
threat, in particular during the transitional period, is insufficiency of initiatives related
to occupational health and safety, including standards and statutory regulations, which
may render them incommensurate in the face of emerging Industry 4.0 technologies.
Furthermore, it may lead to forfeiting the proactive approach to occupational health and
safety that the most industrialized countries have managed to establish. To prevent this
from happening, further research is required to strengthen integration of occupational
health and safety into manufacturing in the context of Industry 4.0. An interdisciplinary
approach should be adopted to this end drawing on the expertise of teams made up of
engineers, IT experts, psychologists, ergonomists, social and occupational scientists,
medical practitioners, and designers. Apart from that, a proactive approach to risk
assessment already at the stage of design or in the early stages of the implementation of
innovation provided by Industry 4.0 and promotion of lifelong learning and continual
professional development is also requisite.
50 A. Polak-Sopinska et al.

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