The Role of Digital Transformation in Manufacturing: Discrete Event Simulation to Reshape Industrial Landscapes

In the era of Industry 4.0, the integration of intelligent systems with human elements presents both opportunities and challenges. This study explores this interplay through the application of an industrial engineering technique to a real process issue, demonstrating originality in problem selection and solution tools, as well as the relevance of the results. An operational framework is proposed to drive digital transformation in manufacturing by balancing automated systems efficiency with the complexity of human activities, which include decision-making flexibility, adaptability, tacit knowledge and collaborative interaction. It examines Industry 4.0 domains to find solutions that use smart technology while enhancing human experience. A key element is the use of discrete-event simulation to create a digital replica of the existing process. This enabled a detailed analysis and the development of innovative, validated approaches through what-if scenarios. The implemented solutions led to a significant annual increase in productivity, the result of an overall improvement in process efficiency, which was also achieved through the identification and resolution of key process bottlenecks, confirming the method’s effectiveness. The research offers a scalable model for various sectors, emphasizing the need to integrate human aspects into intelligent systems. It highlights how technological progress should enrich, not overshadow, human contribution, contributing to a deeper understanding of digital transformation in intelligent manufacturing and service systems, where technology and humanity evolve together.