Applying the Delphi Method to Assess Critical Success Factors of Digitalization While Sustaining Lean at a Lean Automaker

This paper describes the critical success factors for digitalization in manufacturing within the framework of Industry 4.0 and Industry 5.0 while sustaining Lean and Lean-reinforcement links during this transformation within the actual transformation journey of an enterprise (Toyota Motor Europe). In this regard, 11 critical success factors for “digital transformation”, 9 critical success factors for “Lean sustainability”, and 12 reinforcement links (between Lean and digitalization) were identified from the published literature and 56 one-on-one discussions with Toyota Production System experts. Both Lean and digitalization frameworks were developed using the ontology method. Then, a survey with these experts was conducted, in which the Delphi method was used as a survey tool for an analysis, which was performed in three steps: an analysis of psychometric properties was conducted, a stability analysis of the Delphi method was performed, and the significance of non-consensus hypotheses of the results were examined. The results show that “top management commitment” is the most critical factor for digital transformations, whereas for Lean sustainability, it is “keep Genchi Genbutsu (go and see)”. It was found that digitalization impacts Lean very positively (high/strong or high) for a majority of the links and lean on the positive side for the remaining links. These findings can help manufacturing firms make informed decisions regarding minimal waste, lead times, and the right strategy for digitalization.