Lean and Industry 4.0 Strive to Create Smart Factory Through Integration of Systems: An Exploratory Review

Lean manufacturing concept is being widely used for several decades by industries and service organizations to ease operational complexity and enhance productivity. It is so despite the debated criticism about drifting definition and priorities of lean with time. In 1980s, focus of lean was on reduction of waste. Then in 1990s, priority shifted to quality, cost and delivery. Again, in 2000 the focus shifted to customer value. On the other hand, lean experts and authors advocated such changes to be evolutionary and natural with the passing time, keeping the intent of lean intact. On analysis, it is found that lean operates with multi-model advantage using a mix of tools and practices best suited for the company’s position & the type of industry. The lean approach raised excellence of organization to higher level through process standardization, continuous improvement culture development and workers empowerment on production line. Once again, with the changing market expectations many companies require now new approaches to deal with multiple process complexity and operational challenges. Consequently, a usual set of innovative digital technology known as Industry 4.0 and has appeared as new approach in the manufacturing sector. It claims to create a smart system of machines, components, products, properties, process and ICT systems in the whole value chain to partake a smart factory. Lean tools have been using simpler devices to detect abnormalities and stop assembly line or machine to improve human reliability. Systems and devices like ‘andon’, Jidoka, contact sensors, thermocouples, and photoelectric devices are some examples. Industry 4.0 differs in technologies to achieve the common goals as lean but with automation.