Lean 4.0 implementation framework: Proposition using a multi-method research approach

Abstract

This research aims to design an implementation framework for Lean 4.0. First, we identify the synergy elements, barriers, critical success factors, and benefits of integrating Lean manufacturing (LM) practices and Industry 4.0 (I4.0) technologies. Second, we develop a Lean 4.0 framework proposal based on these results. Third, we refine and validate this framework based on lean practitioners’ participation from companies pursuing I4.0 initiatives. In last, we apply the Lean 4.0 framework in a sugar company. We perform a multi-method study employing a scoping review, a systematic literature review, one-to-one interviews, vignette cases with an expert panel, validation of the framework by practitioners, and implementation in an industrial company. We reveal 15 synergy elements based on ten I4.0 technologies and nine LM practices. Further, eight barriers, eight critical success factors, and four clusters based on 22 benefits are identified. Our findings support the proposition of a Lean 4.0 implementation framework and contribute to operations management research theory and practice. Our research addresses the gap regarding an in-depth theoretical study linking LM and I4.0 conjointly with an empirically validated artefact, aiming to integrate their best benefits synergistically. Besides that, our article uses a multi-method approach to building a system-oriented Lean 4.0 implementation framework based on General Systems Theory, containing clear guidelines for framework design and a plan-do-check-act cycle orientation.