Ashok Kumar Mishra, Thakur Abhinav Amar,
Volume 0, Issue 0 (10-2025)
Abstract
The ongoing industrial transformation, Industry 4.0, integrates cyber-physical systems, IoT/IIoT, cloud–edge infrastructures, AI/ML, robotics, and digital twins into manufacturing and supply-chain environments. This paper presents a critical, systematic literature review of 45 peer-reviewed articles (2013–2024) following PRISMA guidelines. We synthesize the conceptual foundations, enabling technologies, applications, benefits, and challenges, and critically assess the transition to Industry 5.0.
Evidence indicates that Industry 4.0 delivers measurable improvements: 10–20% gains in equipment utilization, 15–30% reductions in defects, and 20–40% reductions in downtime when technologies are deployed in integrated configurations (IIoT + digital twin + AI). However, five persistent constraints mediate these benefits: cybersecurity vulnerabilities, high implementation costs (disproportionately affecting SMEs), workforce skills gaps, interoperability deficits, and governance/policy fragmentation.
Significant contradictions in the literature are identified. While some studies report ROI exceeding 30%, fewer than 50% of manufacturing firms achieve positive returns from fragmented deployments. Pilot-to-scale failure is widely acknowledged but rarely quantified. Sustainability claims require rigorous lifecycle assessment due to rebound effects.
Industry 5.0 reorients the trajectory toward human-centricity, sustainability, and resilience. However, it remains conceptually fragmented, policy-driven rather than empirically grounded, with speculative claims about 6G (TRL 2–3) and quantum computing (TRL 1–2). Priority research gaps include longitudinal ROI studies, socio-technical metrics, and comparative policy experiments. This review contributes a critical synthesis and strategic recommendations for academia, industry, and policymakers to achieve equitable and sustainable industrial transformation.
Chaymae Bahtat, Abdellah El Barkany, Abdelouahhab Jabri,
Volume 34, Issue 2 (6-2023)
Abstract
The productivity and flexibility of current manufacturing systems (dedicated and flexible production systems) are no longer competitive as products are developed and brought to market in increasingly shorter cycles. As a result, a new generation of reconfigurable manufacturing systems (RMS) has emerged that should be responsive enough to cope with sudden market changes while maintaining excellent product quality at low prices. These systems could also leverage technologies at the heart of Industry 4.0, such as artificial intelligence and machine learning, the Internet of Things (IoT), and digital twins, to create a smart, dynamic, and most importantly, reconfigurable factory, dubbed the Reconfigurable Factory 4.0. This study provides an organized and up-to-date systematic review of the literature on reconfigurable manufacturing systems, from design to simulation, and from automation to the fourth industrial revolution (Industry 4.0) highlighting the application areas as well as the significant approaches and technologies that have contributed to the development of a Reconfigurable Factory 4.0.
Atef Fakhfakh, Salaheldin Salaheldin, Amr Noureldin, Mohamed Aboueldahab, Neama Elwakeel,
Volume 36, Issue 1 (3-2025)
Abstract
This study investigates the interplay between manufacturing ambidexterity, Industry 4.0 readiness, and sustainable excellence in Egypt's food and beverage sector. It explores how Industry 4.0 readiness mediates and moderates the relationship between ambidexterity and sustainability outcomes. A quantitative research design was employed, utilizing a survey of 308 professionals in Egypt's food and beverage industry. Structural equation modeling (SEM) was used to analyze the relationships among manufacturing ambidexterity, Industry 4.0 readiness, and sustainable excellence. The results reveal that Industry 4.0 readiness fully mediates and significantly moderates the relationship between manufacturing ambidexterity and sustainable excellence. While manufacturing ambidexterity alone does not directly impact sustainable excellence, its effect becomes significant through Industry 4.0 readiness, highlighting the importance of digital transformation. This study focuses on a single sector in Egypt, limiting generalizability. Future research could explore other industries and regions or examine specific dimensions of Industry 4.0 readiness. The findings emphasize the need for organizations to invest in digital infrastructure and foster ambidextrous capabilities to achieve sustainability goals. Policymakers are encouraged to support Industry 4.0 adoption through incentives and training programs to enhance competitiveness and sustainability in emerging markets. This study contributes to the limited research on the application of manufacturing ambidexterity and Industry 4.0 technologies in developing economies, offering insights into achieving sustainable excellence through digital transformation.
Souad Lahmine, Fatima Bennouna,
Volume 36, Issue 2 (6-2025)
Abstract
Quality 4.0 is the fusion between the long-standing quality management tenets and Industry 4.0 technologies like AI, Blockchain, IoT, and Big Data. Although it can improve product quality, control operational efficiency, and supply chain transparency for organizations, adopting these technologies comes with high challenges. This study, therefore, carries out a meta-analytic review incorporating 80 peer-reviewed papers from between 2018 to 2024 to exposit the effectiveness, challenges, and prospects of Quality 4.0. Results show that machine learning-based predictive analytics significantly reduce defect rates and production costs, while Blockchain enhances visibility into the supply chain. On the other hand, organizational readiness and workforce training are major barriers. The paper can give much-needed input to practitioners through actionable recommendations and suggest avenues for further research that would advance Quality 4.0 adoption.
