Optimizing knowledge management integrated with Industry 4.0: a comprehensive case study of smart manufacturing transformation

Purpose This paper aims to show how combining Industry 4.0 (I4.0) technologies with knowledge management (KM) systems can transform manufacturing. By integrating digital tools with effective knowledge-sharing practices, organizations can enhance their performance, become more sustainable and gain a competitive edge. The research highlights how KM is essential for making the most of I4.0’s potential to improve manufacturing processes, collaboration and decision-making. Design/methodology/approach This study uses a robust mixed-methods approach, combining data from a 51-item survey of 120 participants with in-depth interviews conducted with six industry experts. Key I4.0 technologies are examined for their role in enhancing KM and overall organizational outcomes, with reliability ensured by the content validity index (CVI) and Cronbach’s alpha. Findings The results demonstrate that I4.0-KM integration drives remarkable gains in operational efficiency, product customization and environmental sustainability. Widely adopted technologies, while the seamless flow of knowledge enabled by IoT and AI, enhance customization and support advanced analytics. The findings underscore the importance of investing in digital skills and prioritizing data-driven technologies for an accelerated transformation. Practical implications This study offers actionable insights for manufacturers seeking a competitive advantage through Industry 4.0 (I4.0). Focusing on KM systems, digital skill development and strategic technology investment can facilitate a successful shift toward smart manufacturing. Originality/value Offering a unique perspective, this study confirms the powerful impact of I4.0-KM integration on organizational excellence. It demonstrates how advanced knowledge-driven processes directly contribute to performance, sustainability and innovation, providing a valuable roadmap for the future of smart manufacturing.