Exploring the Influence of Operator Features on the Performance of Maintenance Tasks: Insight from Industry Experts

The Industry 5.0 (I5.0) paradigm promotes a human-centric approach to advanced manufacturing by integrating worker well-being with operational performance. Maintenance activities, while not directly value-adding, are crucial to ensuring system reliability and safety. However, the transition to Maintenance 4.0, characterised by the adoption of advanced technologies, has significantly increased the cognitive demands placed on operators. In this regard, it is necessary to develop models and methodologies that allow activities to be assigned to operators by jointly considering the characteristics of the activities to be performed and those of the operator, to ensure their psychophysical well-being. To this concern, this study investigates the operator features most critical for successfully executing maintenance tasks supported by advanced technologies from an I5.0 perspective. Sixteen semi-structured interviews were conducted with experts from various manufacturing sectors to identify key operator skills for technology-supported maintenance under I5.0. The findings highlight fault diagnosis and repair as the most cognitively demanding tasks, requiring the highest levels of competence. Across all maintenance categories, professional training and compliance with technical and safety standards were valued more than formal education. Tasks such as precision cleaning, component replacement, and electrical isolation required significantly more advanced skills than general cleaning or reconnection. Moreover, the importance of cognitive and manual abilities, such as memory, dexterity, and soft skills, varied across task types. These insights support the development of training and task allocation models that better align with I5.0 principles, improving both performance and operator well-being.