Applying Integrated Delphi–AHP to Maintenance Competency Prioritization in Industry 4.0: A Formally Specified Group Decision Framework with Consistency and Sensitivity Diagnostics

As Industry 4.0 transforms manufacturing operations, maintenance organizations face a group decision-making problem: how to consolidate diverse expert judgments into a defensible, transparent ranking of the competencies that maintenance personnel most need. This paper applies an integrated Delphi–AHP framework—with explicit notation, operators, and diagnostics—to prioritize maintenance competencies in advanced-manufacturing settings. The Delphi stage consolidates expert-generated items under median–interquartile-range consensus and round-to-round stability rules, while the Analytic Hierarchy Process (AHP) transforms validated pairwise comparisons into ratio-scale priority weights through geometric-mean Aggregation of Individual Judgments (AIJ) and eigenvector derivation. Consistency screening (CI/CR), inter-rater agreement (Kendall’s W), and perturbation-based sensitivity analysis accompany the resulting weight vector. A bounded AI-assisted consistency-check step supports terminology harmonization during Delphi statement consolidation, subject to explicit human-validation constraints. A panel of fifteen industry experts participated in the study; five competency dimensions and twenty-nine indicators were retained through three Delphi rounds. AHP weighting identified Basic Knowledge and Skills as the highest-priority dimension, followed by Safety and Regulation Awareness and Problem-Solving Ability. Aggregated pairwise comparison matrices, local and global weights, and sensitivity results are reported to support reproducibility. The study contributes a rigorously specified application of combined Delphi–AHP to a domain—Industry 4.0 maintenance asset management—where multi-criteria decision analysis has seen limited formal application, and closes common specification gaps in published Delphi–AHP implementations.