Enhancing Lean Manufacturing Systems with Industry 4.0 Technologies: A Systematic Literature Review

Lean Manufacturing (LM) streamlines production by eliminating waste and enhancing quality through continuous improvement. Industry 4.0 (I4.0) technologies—such as IoT, AI, Big Data Analytics, Cyber-Physical Systems, and Additive Manufacturing—offer opportunities to elevate LM practices. Integrating LM with I4.0, termed Lean 4.0, combines waste-reducing principles with advanced technologies for superior operational performance. This thesis investigates the synergy between LM and I4.0 through a Systematic Literature Review from 2016 to 2024, following PRISMA guidelines, and bibliometric analysis using Python and Bibliometrix. Key findings highlight I4.0 technologies that enhance LM practices, including Just-in-Time inventory management, Total Productive Maintenance, Value Stream Mapping, Kanban systems, and continuous improvement initiatives. Seven major themes emerged: phased technology implementation, impacts on efficiency and performance, integration challenges, development of decision-making frameworks, sustainability practices, sector-specific variations, and leadership and regulatory considerations. The integration offers significant benefits—improved efficiency, quality, flexibility, and sustainability—but presents challenges like technical complexities and organizational resistance. To address these, the study proposes practical frameworks emphasizing strategic leadership to assist organizations in navigating the integration process. By providing updated insights into the integration of LM and I4.0, this research highlights Lean 4.0's potential for sustainable competitive advantage in manufacturing. It offers guidance for practitioners seeking to implement these practices.