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Why “One-Size-Fits-All” DEI Strategies Don’t Work in Australian Manufacturing

Written by: Akash Hettiarachchi, Melinda Laundon, Penny Williams and Greg Hearn, all based at QUT in the Australian Cobotics Centre’s Human‑Robot Workforce program

International Women’s Day is an opportunity to celebrate progress toward gender equity and to reflect on persistent structural challenges in the workplaces. While many sectors highlight successes in advancing gender diversity, Australian manufacturing continues to struggle with its historically male-dominated image. Gender inequality in manufacturing is widely recognised. Yet the sector often progresses with uniform policies and strategies.

Our recent research, published in Equality, Diversity and Inclusion: An International Journal, challenges this approach by revealing that diversity patterns across manufacturing are far more complex, uneven, and sub-sector specific. This study examines workforce diversity across Australian manufacturing using Australian Census data from 2006 to 2021. By analysing trends in gender, generation, ethnicity, disability and educational qualifications across manufacturing sub-sectors, we show why improving gender equity requires targeted, context-specific strategies rather than generic, sector-wide approaches.

Manufacturing Gender Diversity is Uneven and Complex

Australian manufacturing is often described as male-dominated; however, our analysis reveals significant variations in workforce gender diversity across its sub-sectors. The overall representation of women differs considerably among sub-sectors such as food and beverage manufacturing, machinery and equipment manufacturing, and fabricated metal products. This unevenness raises questions about the success of gender-specific diversity strategies and outcomes in Australian manufacturing. Given the diversity composition differences among sub-sectors, broad, blanket gender diversity strategies are unlikely to be effective. Instead, improving gender equity requires a clear understanding of where women are over-represented, under-represented, or entirely absent. It also requires an understanding of how personal, structural, and occupational patterns differ across various manufacturing sub sector contexts.

True Representation is More than Increasing Participation

One of the key findings from our study is that improving gender equity is not simply about increasing the overall number of women in manufacturing. Women are frequently concentrated in specific roles and occupational categories, with limited representation across many technical and operational jobs on the production floor, compared with administrative functions. A focus on numbers alone does not deliver sustainable or meaningful representation in most needed job roles in operations.

These patterns suggest that recruitment focused strategies, while important, are insufficient. Genuine progress requires deeper organisational attention including job design, skills development, promotion pathways, and workplace cultures that support retention and advancement for equal opportunities of all genders. Gender equity in manufacturing is therefore closely tied to how work is organised and how careers are structured, particularly as roles continue to evolve through automation and digitalisation.

Different Generations and Future Skills

Our research highlights a persistent structural challenge within Australian manufacturing: the significant representation of an ageing workforce, alongside ongoing difficulty in attracting younger workers (particularly young women) into manufacturing careers. Despite numerous government initiatives, this imbalance remains largely unchanged.

Older workers continue to play a vital role, contributing critical operational knowledge, continuity, and deep technical expertise. At the same time, long-term workforce sustainability depends on successfully attracting and integrating younger talent. Compared with other sectors, manufacturing has been less successful in renewing its workforce, creating a growing concern for future labour supply.

These demographic dynamics intersect directly with technological change. As Industry 4.0 technologies, including collaborative robots, reshape manufacturing work, new skill demands emerge, often accompanied by workforce adjustment challenges. In response, some organisations must prioritise reskilling existing employees, while others may need to rethink job design and career pathways to better align with evolving technologies and the expectations of a more diverse future workforce.

From a gender equity perspective, this underscores the importance of expanding access — not only to employment, but also to training, reskilling, and progression opportunities. Without deliberate intervention, technological transformation risks reinforcing existing gender patterns rather than enabling more inclusive manufacturing careers.

Why This Matters for Cobotics and The Future Of Work

From the perspective of the Australian Cobotics Centre’s Human‑Robot Workforce research program, these findings reinforce that workforce diversity is central to successful technology adoption. Collaborative robots are introduced into existing workplaces shaped by workforce demographics, skills and organisational practices.

Manufacturing sub‑sectors with different gender profiles and labour market conditions will experience cobot adoption in different ways. Without inclusive workforce strategies, new technologies risk reproducing existing inequalities. Conversely, when job design and skill development are approached with gender equity in mind, collaborative robotics can support safer, more sustainable and more attractive manufacturing work.

Turning Reflection into Sustained Action

International Women’s Day is a useful moment for reflection, but our research highlights the need for ongoing, evidence‑based action. Gender inequality in manufacturing is well recognised, yet it is often oversimplified. Addressing it requires sub‑sector‑specific strategies informed by data and grounded in the realities of different manufacturing contexts.

At the Australian Cobotics Centre Human-Robot Workforce Research Program, this research informs our work on future skills, job design and workforce readiness. Improving gender equity is not separate from productivity or innovation. Rather, it is integral to building a manufacturing workforce capable of adapting to technological change and supporting the long‑term sustainability of Australian industry.

 

Prototyping Possibility: UTS Students Put the Kinematic Puppet to the Test

In Spring 2025, undergraduate engineering students from the University of Technology Sydney (UTS) partnered with the Australian Cobotics Centre (ACC) to explore an innovative prototyping method for human–robot interaction (HRI). As part of the subject 43019 Design in Mechanical and Mechatronic Systems, student teams built and tested the Kinematic Puppet—a low‑cost, modular robot‑skeleton prototyping tool designed to support rapid experimentation with robot morphology, motion and collaborative behaviour.

The puppet’s design combines 3D‑printed joints with magnetic rotary encoders and PVC linkages, giving users a physically manipulable platform for exploring robot movement and interaction in a way that is accessible, intuitive, and adaptable. The motivation for the kinematic puppet was discussed in a previous ACC article.

Building Capability Through Hands‑On Prototyping

The project offered students rich, applied learning opportunities across mechanical engineering, mechatronics, electronics, CAD, and hands‑on fabrication. Assembling the puppet from provided design files required teams to engage deeply with mechanical design principles while developing practical manufacturing skills. Students then used the puppet to prototype real HRI scenarios, experimenting with robot behaviours, designing custom end‑effectors, and capturing motion data based on their task concepts.

Beyond construction, students were asked to use the puppet to prototype HRI scenarios relevant to ACC partners. This shifted the learning experience from purely technical engineering to a more integrated design research mindset. Teams were encouraged to roleplay interactions, test alternative geometries, capture movement data, and reflect on usability. The result was a deeper understanding of how cobot systems behave not just as mechanisms, but as partners in real work environments research mindset. Teams were encouraged to role play interactions, test alternative geometries, capture movement data, and reflect on usability. The result was a deeper understanding of how cobot systems behave not just as mechanisms, but as partners in real work environments.

Real Benefits for the Australian Cobotics Centre

For the ACC, the project delivered meaningful insight into how the Kinematic Puppet performs as an early‑stage cobot‑prototyping tool. Students worked with the puppet across a variety of task types and skill levels, generating feedback on build complexity, robustness, adaptability, and user experience. This diversity of testing environments and techniques offered the Centre a broad evidence base for understanding the puppet’s value and limitations in practical prototyping settings.

The partnership also produced a range of custom tool attachments, demonstration artefacts, and user reports, helping the ACC shape future iterations of the puppet and refine research questions around embodied prototyping for collaborative robotics. These outputs contribute directly to a forthcoming study on the prototyping tools effectiveness as a design and ideation tool for industry‑relevant cobot applications.

A Model for Meaningful Industry–University Collaboration

The Kinematic Puppet project exemplifies the mutual benefits of embedding authentic industry challenges within university engineering curricula. Students gained hands‑on technical experience, confidence in iterative prototyping, and exposure to real‑world HRI design practices. Meanwhile, the Australian Cobotics Centre accessed high‑value feedback, creative exploration, and a new understanding of how early‑stage tools can support collaborative robot development.

By bringing students into the research process, this project created space for innovation, fresh ideas, and critical evaluation, laying groundwork for future cobot systems that are safer, more intuitive, and more attuned to human needs.

I would like to thank the students for their hard work on this impressive project; Lachlan Scott Rogers, Laila Chamma, Mishoura Rahman, Nicholas Uremovic and Tran Thu Nhan Dang. A video summarising the journey of the students can be seen here: Kinematic puppet for cobot prototyping