Smart lean-green framework for sustainable energy optimization and operational excellence in earthmoving equipment manufacturing under Industry 4.0

• Smart Lean-Green Framework enables adaptive energy-aware decision-making in I4.0. • SLGF cut production time by 53% and reduced manufacturing defects by over 90%. • Real-time intelligence optimized workforce, idle time, and non-value-added activities. • IoT, CPS, and big data enhanced scheduling, resource allocation, and uptime by 42.8%. • Framework empowers managers with comfort, clarity, and control on shop floors. Industry individuals face difficulties maintaining operational performance in an Industry environment where organisations continually transform their work platforms and emphasise flexible advancements in shop-floor management. This study addresses the challenges of Industry 4.0-driven shop floor management, considering energy consumption, operational excellence, environmental conditions, and financial viability. There are a few research studies that reported a smart model framework employing a clean lean-green approach to enhance the excellence of operations and the energy management system. The study developed a smart model framework based on lean, green, and clean manufacturing concepts to address operational challenges. This framework was assessed in the earthmoving equipment manufacturing organization. This implementation yielded impressive gains, including a 53.26% reduction in production time, a 91.66% decrease in manufacturing defects, a 53% decrease in idle time, a 46.86% reduction in non-value-added time, and an 18.18% decrease in workforce requirements. These findings demonstrate the efficiency and effectiveness of the smart model framework in enhancing the capabilities of Industry 4.0 operations and energy management. The study strengthens the managerial implications and provides a feasible and realistic platform for regulating operations management.