Engineering for Industry 5.0: Developing Smart, Sustainable Skills in a Lean Learning Ecosystem

As the Industry 5.0 transition unfolds, engineering education must evolve to integrate Lean manufacturing with advanced digital tools and sustainable, human-centred practices. This study presents the design and implementation of a Lean Learning Factory (LLF) that addresses this challenge by combining traditional Lean methods with technologies such as simulation, robotics, and virtual reality in a modular educational environment. At the University Centre Pitești, six hands-on projects were implemented to guide students through key concepts, including production system layout, digital assistance, sustainability, and human–robot collaboration. Through experiential learning, students engage in iterative design, data analysis, and practical validation using real equipment and software platforms. The results indicate that the LLF effectively supports the development of technical, digital, transversal, and human-centred competencies aligned with EUR-ACE® standards. Students acquire skills in process optimisation, ergonomics, and sustainable production, while also reflecting on the ethical and social implications of automation. The study concludes that the LLF model provides a scalable and adaptable framework for engineering education. It fosters competence-based learning and prepares students for the demands of Industry 5.0. This paper contributes a replicable educational approach that blends Lean efficiency, digital transformation, and human-centred values into a cohesive learning ecosystem.