A digital lean world: From digital lean manufacturing to Lean 4.0

This chapter explores the emerging concept of Digital Lean Manufacturing (DLM), which integrates digital technologies with traditional lean manufacturing principles to enhance operational efficiency and competitiveness. DLM, rooted in data acquisition, integration, and analytics, supports the detection, prediction, and prevention of process instabilities, aligning with lean methods such as Jidoka, Kaizen, and Just-in-Time. Industry 4.0 technologies like the Industrial Internet of Things (IIoT), big data, and cyber-physical systems enable smarter, more adaptive production environments. The evolving Lean 4.0 paradigm reflects the convergence of lean principles with advanced digital solutions, driving improvements in productivity, quality, and decision-making. Despite the potential benefits—such as lead-time reductions and increased productivity—challenges remain, including investment costs, technological readiness, and workforce engagement. Future research should focus on integrating Lean 4.0 with Industry 5.0 concepts, emphasizing human-centricity, sustainability, and resilience to achieve long-term industrial success.