The Industry 5.0 Paradox in Textile Manufacturing: Socio-Technical and Behavioral Operations in Production Optimization
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The transition towards Industry 5.0 necessitates a human-centric integration with advanced manufacturing systems. Although Production Planning and Control (PPC) models have mathematically optimised machine parameters, operational inefficiencies and material waste generation remain persistent challenges, particularly in 24/7 yarn spinning industries. This study employs an explanatory quantitative case study approach on a 100% Polyester (PE) yarn production line at PT Excellence Qualities Yarn. Utilising the lenses of Socio-Technical Systems (STS) and Behavioural Operations Management (BOM), this research analyses operational data from the Drawing Breaker machine across three working shifts. The findings reveal significant efficiency variances (Morning Shift: 67.83%; Afternoon Shift: 68.90%; Night Shift: 61.25%). The drastic efficiency drop during the night shift, reaching a low of 28.64% due to 100 minutes of downtime, demonstrates that static technical parameters fail to accommodate the degradation of human capacity. In conclusion, socio-technical imbalances not only reduce production output but also increase material waste ratios, thereby hindering circularity. This research offers novel theoretical insights by bridging machine balancing and operator behavioural factors within industrial sustainability.
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