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This paper aims to analyse the current state of research to identify the link between Lean Manufacturing and Industry 4.0 (I4.0) technologies to map out different research themes, to uncover research gaps and propose key recommendations for future research, including lessons to be learnt from the integration of lean and I4.0.

A systematic literature review (SLR) is conducted to thematically analyse and synthesise existing literature on Lean Manufacturing–I4.0 integration. The review analysed 60 papers in peer-reviewed journals.

In total, five main research themes were identified, and a thematic map was created to explore the following: the relationship between Lean Manufacturing and I4.0; Lean Manufacturing and I4.0 implication on performance; Lean Manufacturing and I4.0 framework; Lean Manufacturing and I4.0 integration with other methodologies; and application of I4.0 technologies in Lean Manufacturing. Furthermore, various gaps in the literature were identified, and key recommendations for future directions were proposed.

The integration of Lean Manufacturing and I4.0 will eventually bring many benefits and offers superior and long-term competitive advantages. This research reveals the need for more analysis to thoroughly examine how this can be achieved in real life and promote operational changes that ensure enterprises run more sustainably.

The development of Lean Manufacturing and I4.0 integration is still in its infancy, with most articles in this field published in the past two years. The five main research themes identified through thematic synthesis are provided in the original contribution. This provides scholars better insight into the existing literature related to Lean Manufacturing and I4.0, further contributing to defining clear topics for future research opportunities. It also has important implications for industrialists, who can develop more profound and richer knowledge than Lean and I4.0, which would, in turn, help them develop more effective deployment strategies and have a positive commercial impact.

Additive manufacturing (AM) is growing economically because of its cost-effective design flexibility. However, it faces challenges such as interlaminar weaknesses and reduced strength because of product anisotropy. Therefore, the purpose of this study is to develop a methodology that integrates design for additive manufacturing (AM) principles with fused filament fabrication (FFF) to address these challenges, thereby enhancing product reliability and strength.

Developed through case analysis and literature review, this methodology focuses on design methodology for AM (DFAM) principles applied to FFF for high mechanical performance applications. A DFAM database is constructed to identify common requirements and establish design rules, validated through a case study.

Existing DFAM approaches often lack failure theory integration, especially in FFF, emphasizing mechanical characterizations over predictive failure analysis in functional parts. This methodology addresses this gap by enhancing product reliability through failure prediction in high-performance FFF applications.

While some DFAM methods exist for high-performance FFF, they are often specific cases. Existing DFAM methodologies typically apply broadly across AM processes without a specific focus on failure theories in functional parts. This methodology integrates FFF with a failure theory approach to strengthen product reliability in high-performance applications.

In recent years, the emergence of Industry 4.0 technologies as a way of increasing productivity has attracted the attention of the manufacturing industry. This study aims to investigate the relationship between Industry 4.0 technologies and lean tools (LTs) by measuring how the internalisation of LTs influences the adoption of Industry 4.0 technologies and how the synergy between them helps improve productivity in European manufacturing firms.

Results from 1,298 responses were used to analyse linear regression and study the correlation between the use of LTs and Industry 4.0 technologies.

Results show that the companies analysed tend to implement more Industry 4.0 technologies when their level of lean internalisation is high.

This study provides useful information for managers of manufacturing firms by showing the correlation between LT internalisation and Industry 4.0 technologies, corroborating that optimal implementation of these technologies is preceded by a high level of LT internalisation. Furthermore, although there are studies showing the relationship between LTs and Industry 4.0 technologies, none consider the intensity of their implementation.

This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).

PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.

Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.

This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

Circular supply chain management (CSCM) is considered a promising solution to attain sustainability in the current industrial system. Despite the exigency of this approach, its application in the food industry is a challenge because of the nature of the industry and CSCM being a novel approach. The purpose of this study is to develop an industry-based systematic analysis of CSCM by examining the challenges for its application, exploring the effects of recognised challenges on various food supply chain (FSC) stages and investigating the business processes as drivers.

Stakeholder theory guided the need to consider stakeholders’ views in this research and key stakeholders directly from the food circular supply chain were identified and interviewed (n = 36) following qualitative methods.

Overall, the study reveals that knowledge, perception towards environmental initiatives and economic viability are the major barriers to circular supply chain transition in the UK FSC.

This research provides a holistic perspective analysing the loopholes in different stages of the supply chain and investigating the way a particular circular supply chain stage is affected by recognised challenges through stakeholder theory, which will be a contribution to designing management-level strategies. Reconceptualising this practice would be beneficial in bringing three-tier (economic, environmental and social) benefits and will be supportive to engage stakeholders in the sustainability agenda.

Manufacturers face various challenges and risks during their digital servitization (DS), due to the complexity caused by introducing breakthrough technologies, increasingly complex product-service solutions and new stakeholders in the business network. The process necessitates the implementation of various changes that usually happen over a long period of time. Using complexity management as a theoretical lens, this paper delves into manufacturers’ DS journeys and explores how manufacturers manage the associated complexities.

This paper investigates the DS journey of two manufacturers in a longitudinal case study from 2014 to 2021.

Three main complexity management actions during the DS journey were identified: shaping the digital service system, shaping the organization and shaping the network. Tied to different types of complexities, these actions demonstrate how manufacturers navigate their journey. The findings also reveal different complexity management approaches used at the different stages of this journey.

This paper offers a comprehensive framework for understanding complexity management in the DS journey, including the types of complexities, complexity management actions and complexity management approaches and their rationale. This paper shows that different requirements are created during emerge, consolidate and evolve stages of the DS journey. Manufacturers need a dynamic approach that considers changes in complexities and actions over time.

Quality has always been a competitive advantage for every organisation that strives for customer satisfaction when offering services or products. Technological advancements during the industrial revolutions have enabled organisations to grub improvement and transition opportunities into a new paradigm in operating business processes. In light of the fourth industrial revolution (FIR), in which Quality 4.0 (Q4.0) leveraged its technologies, this study establishes the need for service organisations to transition to Q4.0. It unveils the awareness level within the organisation, the existing challenges and the benefits of transitioning to Q4.0.

The data for this study was acquired through a survey methodology; it involved qualitative and quantitative methodologies and a mix of primary and secondary sources. The challenges and benefits regarding Q4.0 adoption were obtained from the relevant literature and used as a base of assessment in the selected service organisations. Minitab version 20 and SPSS 21.0 software packages analysed the gathered data.

The study found a high level of awareness regarding Q4.0 among the selected service organisations. Despite the high level of awareness, it was revealed that neither of the Q4.0-related technologies have been implemented nor in the process within the selected service industries. This is due to numerous challenges, including inadequate high-speed internet, a high cost of investment, inadequate skilled personnel and inadequate scepticalness to the implementation outcomes. Despite these challenges, leveraged technologies, potential benefits and Q4.0 awareness all demonstrate the need for Q4.0.

The study introduces the advent of the FIR and the disruptive nature of the associated technologies. It also unveils the potential of the contemporary technologies of the FIR that could elevate quality service provision to increase their competitiveness. Moreover, it also assists service organisations in planning and properly allocating their resources to ensure all the challenges are addressed in the Q4.0 adoption process. The study is limited in that it merely considers service organisations in Tanzania without categorising what type of service organisations were considered, i.e. banking, telecommunications, health, etc. thus generalising the findings.

Much has been discussed in the literature regarding Q4.0 in manufacturing organisations, focusing less on service organisations. This study uniquely assessed the need to transition to Q4.0 for service organisations, which has yet to be covered in the literature.

The study aims to identify Green Lean Six Sigma (GLSS) barriers in the context of Higher Education Institutions (HEIs) and prioritize them for executing the GLSS approach.

A systematic literature review (SLR) was used to identify a total of 14 barriers, which were then verified for greater relevance by the professional judgments of industrial personnel. Moreover, many removal measures strategies are also recommended in this study. Furthermore, this work also utilizes Gray Relational Analysis (GRA) to prioritize the identified GLSS barriers.

The study reveals that training and education, continuous assessment of SDG, organizational culture, resources and skills to facilitate implementation, and assessment of satisfaction and welfare of the employee are the most significant barriers to implementing this approach.

The present study provides an impetus for practitioners and managers to embrace the GLSS strategy through a wide-ranging understanding and exploring these barriers. In this case, the outcomes of this research, and in particular the GRA technique presented by this work, can be used by managers and professionals to rank the GLSS barriers and take appropriate action to eliminate them.

The ranking of GLSS barriers gives top officials of HEIs a very clear view to effectively and efficiently implementing GLSS initiatives. The outcomes also show training and education, sustainable development goals and organizational culture as critical barriers. The findings of this study provide an impetus for managers, policymakers and consultants to embrace the GLSS strategy through a wide-ranging understanding and exploring these barriers.

The GLSS barriers in HEIs may significantly affect the society. HEIs can lessen their environmental effect by using GLSS practices, which can support sustainability initiatives and foster social responsibility. Taking steps to reduce environmental effect can benefit society as a whole. GLSS techniques in HEIs can also result in increased operational effectiveness and cost savings, which can free up resources to be employed in other areas, like boosting student services and improving educational programs. However, failing to implement GLSS procedures in HEIs could have societal repercussions as well. As a result, it is critical for HEIs to identify and remove GLSS barriers in order to advance sustainability, social responsibility and operational effectiveness.

GLSS is a comprehensive methodology that facilitates the optimum utilization of resources, reduces waste and provides the pathway for sustainable development so, the novelty of this study stands in the inclusion of its barriers and HEIs to prioritize them for effective implementation.

This paper explores Lean Six Sigma principles and the DMAIC (define, measure, analyze, improve, control) methodology to propose a new Lean Six Sigma 4.0 (LSS 4.0) framework for employee occupational exams and address the real-world issue of high-variability exams that may arise.

This study uses mixed methods, combining qualitative and quantitative data collection. A detailed case study assesses the impact of LSS interventions on the exam management process and tests the applicability of the proposed LSS 4.0 framework for employee occupational exams.

The results reveal that changing the health service supplier in the explored organization caused a substantial raise in occupational exams, leading to increased costs. By using syntactic interoperability, lean, six sigma and DMAIC approaches, improvements were identified, addressing process deviations and information requirements. Implementing corrective actions improved the exam process, reducing the number of exams and associated expenses.

It is important to acknowledge certain limitations, such as the specific context of the case study and the exclusion of certain exam categories.

The practical implications of this research are substantial, providing organizations with valuable managerial insights into improving efficiency, reducing costs and ensuring regulatory compliance while managing occupational exams.

This study fills a research gap by applying LSS 4.0 to occupational exam management, offering a practical framework for organizations. It contributes to the existing knowledge base by addressing a relatively novel context and providing a detailed roadmap for process optimization.

The purpose of this study is to present a methodical procedure on how to prepare event logs and analyse them through process mining, statistics and visualisations. The aim is to derive roots and patterns of quality deviations and non-conforming finished products as well as best practice facilitating employee training in the food processing industry. Thereby, a key focus is on recognising tacit knowledge hidden in event logs to improve quality processes.

This study applied process mining to detect root causes of quality deviations in operational process of food production. In addition, a data-ecosystem was developed which illustrates a continuous improvement feedback loop and serves as a role model for other applications in the food processing industry. The approach was applied to a real-case study in the processed cheese industry.

The findings revealed practical and conceptional contributions which can be used to continuously improve quality management (QM) in food processing. Thereby, the developed data-ecosystem supports production and QM in the decision-making processes. The findings of the analysis are a valuable basis to enhance operational processes, aiming to prevent quality deviations and non-conforming finished products.

Process mining is still rarely used in the food industry. Thereby, the proposed method helps to identify tacit knowledge in the food processing industry, which was shown by the framework for the preparation of event logs and the data ecosystem.