Industry 4.0-driven digital transformation for resilient aerospace supply chains: a comprehensive review

Purpose This review aims to examine how Industry 4.0 (I4.0)-driven digital transformation can enhance supply chain resilience (SCR) in the aerospace sector. It aims to synthesize evidence on the benefits, challenges and strategic implications of integrating advanced digital technologies into aerospace supply networks to withstand and adapt to disruptions. Design/methodology/approach The authors conduct a systematic review with a structured critical appraisal. For each technology–resilience link the authors classify study design (conceptual vs empirical), sector specificity (aerospace vs cross-industry) and relative effect direction; the authors also grade evidential strength and identify boundary conditions (certification, cyber-risk, organizational readiness). The study categorizes I4.0 technologies – including IoT, big data analytics, artificial intelligence, cloud computing, blockchain, additive manufacturing and digital twins – and maps their resilience-enhancing mechanisms (e.g. visibility, velocity, flexibility, collaboration, risk culture) to different disruption phases. Case studies and empirical findings from aerospace and comparable industries are analyzed to assess practical outcomes, challenges and integration strategies. Findings The review finds that I4.0 technologies can significantly strengthen aerospace SCR by enabling real-time visibility, predictive risk analytics, agile decision-making and on-demand manufacturing. Evidence from COVID-19 and other disruptions shows that digitally enabled aerospace firms achieved faster recovery and maintained continuity more effectively than less-digitized counterparts. However, high implementation costs, legacy system integration hurdles, cybersecurity risks, skills gaps and cultural resistance remain major barriers. Successful adoption requires strategic alignment, organizational readiness, cross-firm collaboration and continuous improvement. Originality/value Beyond synthesis, this review offers a critical appraisal of the strength, limits and contingencies of the evidence linking I4.0 to resilience in aerospace, including where empirical support is weak or mixed. The authors introduce an evidence-grading “map” that identifies boundary conditions (e.g. certification, cybersecurity, SME readiness) and delineates when specific technologies measurably improve robustness, agility and recovery.