IPDEXO : towards an IPD framework for designing smart exoskeletons as socio-technical systems for Industry 5.0

Abstract

Industry 5.0 re-centres manufacturing around people, yet many shop-floor tasks remain resistant to automation because they demand dexterity, judgement, and adaptability, while imposing simultaneous physical and cognitive strain. Existing exoskeleton adoption approaches under-address this “dual load” reality and rarely treat integration with DMSs as a first-class design and implementation concern through an IPD lens. This study combines a state-of-the-art review and semi-structured interviews with two contrasting case studies (toolroom maintenance and food production), applying IDEF0 modelling, feasibility analysis, and Quality Function Deployment to translate evidence into requirements, integration points, and design direction. This resulted in a novel IPDEXO framework: a phased, three pillar (business–design–production) prescriptive model, refined through evaluation feedback, and demonstrated through a modular smart exoskeleton concept and proof-of-concept scenarios, such as AR-guided industrial work and ERP linked traceability.