The United Kingdom’s automotive production sector is experiencing a fifth industrial revolution (5IR). Although the fourth industrial revolution (4IR) started just over one decade ago, the next generation of advanced robotics in manufacturing has already arrived.

The Advanced Robotics Revolution Is Underway

Technological advancement is accelerating exponentially. Even though 4IR began in the mid-2010s, 5IR was already underway by the 2020s. The distance between the two is much shorter than the gap of several decades that came between the third and fourth. Despite the short notice, automotive factories in the U.K. are already adopting the latest technologies.

Sophisticated robotics, interconnected nodes, autonomous algorithms, advanced analytics and machine intelligence are the driving forces behind 5IR. They are facilitating collaboration at an unprecedented scale, demonstrating the synergy between humans and technology in machine-based production applications.

In contrast to 4IR, 5IR focuses on human-machine interactions. Research shows productivity has slowed worldwide after the inception of Industry 4.0 — likely because manufacturing leaders have only thought about replacing workers with emerging technologies.

Advanced robotics in manufacturing have blurred the line between machine and man. Industry 5.0 seeks to clear the haze by prioritising collaboration. This innovative line of thinking may be why it reached $65.8 billion in 2024, with projections placing its value at $255.7 billion by 2029. It could achieve a 31.2% compound annual growth rate.

UK Plants Have Embraced Industry 5.0 Solutions

The United Kingdom’s automotive industry has been among the first to embrace 5IR solutions. For instance, BMW has deployed an autonomous four-legged robot at its Hams Hall petrol engine production plant. It uses a Boston Dynamics model named Spotto to streamline maintenance, monitor production lines and feed data into connected devices.

The so-called robot dog can climb stairs, cross uneven ground and right itself if it falls over, enabling it to move throughout the factory unhindered. It uses thermal, visual and sound sensors to gather data about its environment in real time, which it feeds to a digital twin — a three-dimensional copy of the U.K. production plant.

Engineers have also been busy. In a first for the world, robot-led safety inspections were conducted at a U.K. nuclear plant. Traditionally, operators use human-controlled robots to inspect and repair because prolonged exposure to the power plant’s environment is dangerous to humans.

Thanks to the collaboration between Oxford Robotics Institute and the United Kingdom Atomic Energy Authority, a proof of concept for advanced robotics in engineering now exists. Like BMW, the group used the quadruped model from Boston Dynamics. It conducted safety inspections twice daily for over one month.

Interestingly, these are some of the few U.K. companies embracing 5IR. Most are still adopting Industry 4.0 solutions and have yet to move on fully. However, those who have embraced the next generation of advanced robotics in manufacturing are already seeing results. Early adopters are compiling massive amounts of data and improving employee productivity.

Why These Factory Innovations Are Catching On

Labour productivity has been a pain point in the U.K. for decades. Historically, it has increased by roughly 2% annually. However, since the 2008 recession, it has slowed. Compared to the United States, the country’s productivity rate — gross domestic product (GDP) per hour, specifically — was 18% lower as of 2024.

With Industry 5.0, manufacturers can overcome stagnating productivity levels, increasing output per hour worked while reducing unplanned downtime. This is particularly beneficial since the Institute of the Motor Industry predicts the employment replacement demand in the U.K. automotive manufacturing sector will reach nearly 160,000 openings by 2031.

Another benefit of adopting Industry 5.0 is the simplification of compliance. International standards like ISO 90001 specify requirements for quality, enabling factories to demonstrate their ability to consistently produce parts that meet customer and regulatory expectations. Typically, manual audits and reporting are time-consuming and complex.

With autonomous robotics, manufacturing workers can streamline repetitive compliance requirements. Whether they need to conduct routine safety inspections or aggregate reports on the production line, they can deploy AI-powered robots.

Autonomous robots enable efficient resource utilisation, lowering production costs and making vehicles more affordable for U.K. consumers. For example, one factory’s advanced paint gun manipulator achieves 100% transfer efficiency without over-spraying. In addition to eliminating waste, it improves energy efficiency by reducing the need for ventilation.

What Will Help More Auto Factories Embrace 5IR?

Although many U.K. plants have embraced Industry 5.0, many have only tentatively invested in a handful of 5IR technologies. One of the main reasons for this is the cost of upgrading. The third industrial revolution lasted for decades, giving manufacturers enough time to receive a return on investment. The latest technological advancements came much earlier than many expected.

Risk-averse decision-makers have held off integrating advanced robotics into manufacturing because they prioritise financial flexibility. Many are waiting for a proof of concept or a successful trial before committing to an upgrade. For now, many remain in Industry 4.0.

The U.K. hasn’t yet matched other countries’ investments in advanced automation — despite outranking many for the number of robots per 10,000 workers. If it prioritises investments, it could increase the GDP by 3.2% by 2030. Moreover, it could upskill workers, enabling it to fill 42% of unfilled positions. This move would add £7 billion to the U.K. GDP annually.

Industry 5.0 is still relatively new. It will become more prevalent as more trials succeed and investment costs lower. For now, the lack of industry-wide adoption isn’t a matter of an absence of demand — it is a matter of timing. More automotive production plants will turn to 5IR solutions to improve their workflows as soon as they secure funding or see risks reduced.

The Future of Advanced Robotics in Manufacturing

Forward-thinking factories integrating advanced robotics into manufacturing will benefit in several ways and gain a competitive advantage. As a result, their investment decisions will hold weight, driving the robotics revolution. Only time will tell what trends catch on.