Smart MES in Industry 5.0: How Machine Learning Revolutionizes Continuous Improvement in Renewable Energy
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Smart MES in Industry 5.0: How Machine Learning Revolutionizes Continuous Improvement in Renewable Energy

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Martin Szerment

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Published on June 26, 2025

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ROI: up to 15% efficiency gains and 10–20% better energy storage performance – this is the real power of AI in modern energy.

In the era of Industry 5.0, where technology merges with a human-centric approach, the renewable energy sector is growing at an unprecedented pace – with 18.6 GW of additional solar capacity installed in the first nine months of 2024.
Manufacturing Execution Systems (MES) enhanced with machine learning are becoming a cornerstone of this transformation, delivering both business and technical benefits.

MES Market – The Numbers

  • Global MES market: 15–17B(2024)∗∗→forecasted∗∗15–17B (2024)** → forecasted **27–42B (2030–2032)

  • CAGR: 9.4–14.1%

  • 51% of revenues come from services

  • Asia-Pacific leads with 29.7% share, driven by initiatives like Made in China 2025

Industry 5.0 vs Industry 4.0

  • Industry 4.0 = automation & digitalization

  • Industry 5.0 = human-centric, sustainable, resilient manufacturing + intuitive human–machine collaboration

Machine Learning in MES – Real Benefits

Predictive maintenance & optimization

  • +15% network efficiency

  • +10–20% energy storage improvement

  • SVR: MSE 2.002 (PV), 3.059 (wind)

  • Random Forest: –8.5% prediction error

  • ROI: 18–24 months

Smart forecasting & grid management

  • Real-time balancing of supply & demand

  • Grid stability optimization

  • Intelligent demand response

MES with ML – System Architecture

  • Data layer: IoT sensors, SCADA, PLCs, edge computing

  • ML layer: LSTM, Random Forest, SVM, ARIMA, anomaly detection

  • Interface layer: intuitive HMIs, AR for operators, collaborative robots (cobots)

Implementation phases:

  1. Assessment & planning (2–4 months)

  2. Pilot (4–6 months)

  3. Full rollout (6–12 months)

Case Studies

Smart Solar Farm, Spain (500 MW):

  • +12% production

  • –25% downtime

  • ROI: 16 months

Offshore Wind Farm, North Sea (150 turbines):

  • –30% unplanned downtime

  • €2.3M annual savings

  • +18% availability factor

Challenges & Barriers

  • Technical: legacy integration, protocol standardization, real-time data, cybersecurity

  • Organizational: change management, workforce upskilling, high CAPEX vs. proven ROI

The Future – Trends

  • Quantum computing for energy simulation

  • Green IT & circular economy

  • Blockchain for energy trading

  • By 2030: PV & wind >50% of global electricity

Bottom Line

  • +15% efficiency gains

  • ROI: 18–24 months

  • Reduced prediction errors

Industry 5.0 is not about if but when and how fast.
The future of energy is human + machine working together for a sustainable and profitable tomorrow. The time to act is now.

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