Crafting a synergistic convergence: an integrated approach for lean and industry 4.0 transformation

This paper presents an integrated approach that combines Lean principles with Industry 4.0 (I4.0) technologies, exploring how Lean tools intersect with and adapt to digital advancements. Using an inductive grounded theory methodology, qualitative data were gathered from 22 in-depth interviews with 15 large Italian manufacturing companies that have mature Lean practices. Seven key categories emerged from the analysis. The findings reveal the importance of leadership, raising awareness, and developing employee skills to navigate digital transformation, while addressing concerns during this process. The study highlights how some Lean tools were modified or replaced with I4.0 technologies, enhancing employees’ autonomy and predictive capabilities. It also identifies a redefinition of kaizen activities, with opportunities to leverage analytics and AI in continuous improvement initiatives. These insights fill a gap in the literature by offering evidence and practical guidelines for integrating Lean and I4.0. The research further dispels the misconception that Lean merely serves as a starting point for digital transformation, arguing that the sequence of integration depends on the specific context.