Authors: Lavanya Bhatia, Akhil Das
Abstract: In today’s competitive manufacturing landscape, achieving operational excellence requires a strategic fusion of traditional process optimization and emerging digital technologies. Lean manufacturing, with its focus on waste elimination and process efficiency, has been a cornerstone in operational management for decades. Industry 4.0, characterized by automation, connectivity, and real-time data analytics, introduces intelligent tools for transforming operations. This paper explores the integration of Lean principles with Industry 4.0 technologies—forming hybrid frameworks that offer synergistic benefits. The study analyzes how digital tools such as IoT, AI, and cyber-physical systems enhance Lean tools like Value Stream Mapping (VSM), 5S, and Kaizen. Real-world implementations, challenges in integration, and key enablers for success are also discussed. The paper concludes by proposing a structured hybrid framework to guide industries in achieving sustained operational excellence.
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