In the era of the fourth industrial revolution, human has still a central role. Manufacturing industries have to deal with human sustainability in order to guarantee workers’ health and well-being. Several studies have proved the importance of ergonomics in workplace design and the benefits related to the adoption of the human-centered approach. The enabling technologies of Industry 4.0 are changing the role of the operator and can support him from a physical and cognitive point of view. On the other hand, companies are increasingly implementing lean philosophies, such as World Class Manufacturing, to maintain their competitiveness by reducing wastes and costs. However, the need arises for a comprehensive methodology to support the design of manufacturing equipment considering human factors by integrating Industry 4.0 technologies and World Class Manufacturing elements. It aims at improving both ergonomic and efficiency aspects of the workstation. The proposed methodology allows identifying and in-depth analyzing the problem, thus finding and implementing a solution that complies with all the requirements and constraints defined. Each step of the methodology can be strengthened by Industry 4.0 technologies. The methodology has been experimented in a real case study with a global company of agriculture and industrial vehicles, leading to the design and implementation of a new equipment. Relevant benefits in terms of ergonomics, efficiency, and process standardization have been achieved.

Industry 5.0 envisions a future where seamless collaboration between humans and robots enhances efficiency, innovation, and coevolution. While collaborative robots have found widespread applications in manufacturing, particularly in tasks like pick-and-place and assembly, their integration into handcrafted manufacturing processes presents unique challenges. This article focuses on advancing technology in the less-explored field of cobot-assisted handcrafted manufacturing, specifically in the fashion industry, with a priority on reducing work-related risks. In handcrafted processes, which often involve intricate and artistic work, cobots face challenges related to nuanced decision-making, adaptability to customizations, and the need for precise manual dexterity. The study delves into the cobot-assisted polishing of leather shoes, addressing issues associated with product delicacy, process and knowledge formalization, versatility, and integration into existing manufacturing processes. To overcome these challenges, the research proposes the application of cobots in the initial polishing phase, which is the most physically demanding, allowing artisans to focus on finalization, quality control, and process supervision. The study also applies the concept of human-in-the-loop (HITL) and virtual reality simulation to optimize collaboration, ensuring safety, ergonomics, and efficiency. The article contributes to the scientific and industrial communities by pioneering the study of collaborative robotics in craftsmanship, successfully implementing human–robot collaboration (HRC) in an industrial setting, demonstrating the effectiveness of virtual simulation and HITL, and prioritizing human factors throughout the design and development of HRC. The insights gained from this research are crucial for achieving practical solutions in industrial environments while aligning with the performance objectives of companies and workers’ well-being.