Design and empirical validation of Lean 4.0: a systemic approach to smart lean production

Purpose This study aims to integrate Industry 4.0 (I-4.0) technologies with Lean principles, proposing a framework called “Lean 4.0” to improve production efficiency and quality. Design/methodology/approach This study was conducted in several steps. First, the objectives of this study were defined. Second, a systematic literature review was conducted to identify research gaps in integrating I-4.0 into lean production (LP). Third, the “Lean 4.0” framework was designed based on general systems theory (GST). Fourth, a pilot study was carried out in a controlled environment to validate the proposed framework empirically. Finally, an overall summary of this study was produced, highlighting the limitations and contributions of the proposed “Lean 4.0” framework. Findings An improved integration framework, “Lean 4.0,” was designed and proposed to the scientific community. In addition, the demonstration of the proposed framework in a controlled lab environment shows that merging Lean and I-4.0 can significantly improve the production floor’s overall equipment effectiveness, emphasizing the potential for digital transformation of the LP system. Research limitations/implications This study was conducted in a controlled educational laboratory, which may not reflect the complexities of real-world manufacturing environments. Thus, additional research is needed to validate the “Lean 4.0” framework across different industries to assess its effectiveness and adaptability. Originality/value The proposed framework was validated through a pilot study, which provided the first empirical evidence for the scientific community. In addition, the framework is grounded in GST, ensuring a structured and holistic approach. Its content was also validated through expert opinions, making this framework a pioneering effort in its field.