Artificial Intelligence for Adaptive Safety and Task Allocation in Smart Manufacturing: A Comprehensive Review

Artificial intelligence (AI) is transforming smart manufacturing by enabling intelligent automation, data-driven decisions, and stronger collaboration between humans and manufacturing systems. The widespread adoption of collaborative robots, the industrial internet of things, and cyber-physical systems is driving demand for manufacturing environments that are safer, more flexible, and more efficient. Despite AI’s broad application in manufacturing, few studies have combined adaptive safety and intelligent task allocation within a single human-centered framework. This review offers a comprehensive look at AI applications that support these two complementary functions. Literature from Scopus, Web of Science, IEEE Xplore, ScienceDirect, SpringerLink, and the ACM Digital Library was systematically reviewed following the Preferred Reporting Items for Systematic Reviews and Meta-Analyses guidelines and analysed thematically. The findings show that machine learning, deep learning, computer vision, reinforcement learning, knowledge-driven approaches, digital twins, and explainable AI contribute to improvements in predictive maintenance, quality inspection, production scheduling, adaptive safety, and collaborative decision-making. That said, challenges remain - such as interoperability, explainability, limited access to high-quality manufacturing data, industrial validation, and integrating multiple AI technologies. This review gives researchers and practitioners a holistic perspective and highlights integrated, human-centered AI frameworks as key enablers of resilient, efficient, and sustainable Industry 5.0 manufacturing systems.