Predictive Maintenance (PdM) is a prominent strategy comprising all the operational techniques and actions required to ensure machine availability and to prevent a machine-down failure. One of the main challenges of PdM is to design and develop an embedded smart system to monitor and predict the health status of the machine. In this work, we use a data-driven approach based on machine learning applied to woodworking industrial machines for a major woodworking Italian corporation. Predicted failures probabilities are calculated through tree-based classification models (Gradient Boosting, Random Forest and Extreme Gradient Boosting) and calculated as the temporal evolution of event data. This is achieved by applying temporal feature engineering techniques and training an ensemble of classification algorithms to predict Remaining Useful Lifetime (RUL) of woodworking machines. The effectiveness of the proposed method is showed by testing an independent sample of additional woodworking machines without presenting machine down. The Gradient Boosting model achieved accuracy, recall, and precision of 98.9%, 99.6%, and 99.1%. Our predictive maintenance approach deployed on a Big Data framework allows screening simultaneously multiple connected machines by learning from terabytes of log data. The target prediction provides salient information which can be adopted within the maintenance management practice.

This study contributes to understanding semi-automated ergonomic risk assessments in industrial manufacturing environments, proposing a practical tool for enhancing worker safety and operational efficiency. In the Industry 5.0 era, the human-centric approach in manufacturing is crucial, especially considering the aging workforce and the dynamic nature of the entire modern industrial sector, today integrating digital technology, automation, and sustainable practices to enhance productivity and environmental responsibility. This approach aims to adapt work conditions to individual capabilities, addressing the high incidence of work-related musculoskeletal disorders (MSDs). The traditional, subjective methods of ergonomic assessment are inadequate for dynamic settings, highlighting the need for affordable, automatic tools for continuous monitoring of workers’ postures to evaluate ergonomic risks effectively during tasks. To enable this perspective, 2D RGB Motion Capture (MoCap) systems based on computer vision currently seem the technologies of choice, given their low intrusiveness, cost, and implementation effort. However, the reliability and applicability of these systems in the dynamic and varied manufacturing environment remain uncertain. This research benchmarks various literature proposed MoCap tools and examines the viability of MoCap systems for ergonomic risk assessments in Industry 5.0 by exploiting one of the benchmarked semi-automated, low-cost and non-intrusive 2D RGB MoCap system, capable of continuously monitoring and analysing workers’ postures. By conducting experiments across varied manufacturing environments, this research evaluates the system’s effectiveness in assessing ergonomic risks and its adaptability to different production lines. Results reveal that the accuracy of risk assessments varies by specific environmental conditions and workstation setups. Although these systems are not yet optimized for expert-level risk certification, they offer significant potential for enhancing workplace safety and efficiency by providing continuous posture monitoring. Future improvements could explore advanced computational techniques like machine learning to refine ergonomic assessments further.

Advanced Driver-Assistance Systems (ADASs) are used for increasing safety in the automotive domain, yet current ADASs notably operate without taking into account drivers’ states, e.g., whether she/he is emotionally apt to drive. In this paper, we first review the state-of-the-art of emotional and cognitive analysis for ADAS: we consider psychological models, the sensors needed for capturing physiological signals, and the typical algorithms used for human emotion classification. Our investigation highlights a lack of advanced Driver Monitoring Systems (DMSs) for ADASs, which could increase driving quality and security for both drivers and passengers. We then provide our view on a novel perception architecture for driver monitoring, built around the concept of Driver Complex State (DCS). DCS relies on multiple non-obtrusive sensors and Artificial Intelligence (AI) for uncovering the driver state and uses it to implement innovative Human–Machine Interface (HMI) functionalities. This concept will be implemented and validated in the recently EU-funded NextPerception project, which is briefly introduced.

This paper introduces a low-cost and low computational marker-less motion capture system based on the acquisition of frame images through standard RGB cameras. It exploits the open-source deep learning model CMU, from the tf-pose-estimation project. Its numerical accuracy and its usefulness for ergonomic assessment are evaluated by a proper experiment, designed and performed to: (1) compare the data provided by it with those collected from a motion capture golden standard system; (2) compare the RULA scores obtained with data provided by it with those obtained with data provided by the Vicon Nexus system and those estimated through video analysis, by a team of three expert ergonomists. Tests have been conducted in standardized laboratory conditions and involved a total of six subjects. Results suggest that the proposed system can predict angles with good consistency and give evidence about the tool’s usefulness for ergonomist.