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The rapid advancement of technology related to Industry 4.0 has brought about a paradigm shift in the way we interact with assets across various domains. This progress has led to the emergence of the concept of a Human Digital Twin (HDT), a virtual representation of an individual’s cognitive, psychological, and behavioral characteristics. The HDT has demonstrated potential as a strategic tool for enhancing productivity, safety, and collaboration within the framework of Industry 5.0. In response to this challenge, this paper outlines a process for tracking human cognitive load using the galvanic skin response as a physiological marker and proposes a novel method for managing cognitive load based on the extended Human Asset Administration Shell (HAAS). The proposed HAAS framework integrates real-time data streams from wearable sensors, user skills, contextual information, task specifics, and environmental and surrounding conditions to deliver a comprehensive understanding of an individual’s cognitive state, physical wellness, and skill set. Through the incorporation of skills set, physical, physiological, and psychological variables, and task parameters, the developed HAAS framework enables the identification, management, and development of individual capabilities, thereby facilitating individualized training and knowledge exchange. The applicability of the developed framework is proved by an experiments in the Operator 4.0 laboratory with the detailed HAAS parameters.

The ongoing Industry 4.0 is characterized by the connectivity between components in the manufacturing system. For modern machines, the Internet of Things is a built-in function. In contrast, there are legacy machines in deployment functioning without digital communication. The need to connect them became popular to improve overall production efficiency. As building a new smart factory as a greenfield investment is a capital-intensive choice, retrofitting the existing infrastructure with IoT capability is more reasonable than replacing them. However, this so-called brownfield development, or retrofitting, requires specific prerequisites, e.g., digitization status assessment, technical and connectivity development, management requirement, and operational need, representing a significant disadvantage: lack of scalability. In the meantime, Industry 5.0 is under human-centric priority, which poses new challenges to the retrofitted system. Aware of the challenge, this paper provides a systematic overview of brownfield development regarding technical difficulties, supporting technologies, and possible applications for the legacy system. The research scope focuses on available Industry 4.0 advancements but considers preparing for the forthcoming Industry 5.0. The proposed retrofitting project approach can be a guideline for manufacturers to transform their factories into intelligent spaces with minimal cost and effort but still gain the most applicable solution for management needs. The future direction for other research in brownfield development for Industry 5.0 is also discussed.