Advancing Kaizen 4.0 for Smart Manufacturing Excellence: A Comprehensive Review and Conceptual Framework for Continuous Improvement

Abstract

The rapid advancement of Industry 4.0 technologies transforms manufacturing systems and redefines traditional continuous improvement practices. Kaizen 4.0 evolves classical Kaizen—rooted in incremental, employee-driven improvement—by integrating digital technologies such as the Internet of Things (IoT), Artificial Intelligence (AI), Big Data, and Digital Twins to support smart manufacturing excellence. This paper critically reviews contemporary Kaizen literature, examining its historical development, methodological advancements, and cross-industry applications, while addressing the challenges of aligning continuous improvement with digital transformation. Based on these insights, a conceptual Kaizen 4.0 framework is proposed, structured around five key pillars: enhancing employee-driven initiatives through real-time analytics and automation; integrating Lean tools such as Value Stream Mapping (VSM), Total Productive Maintenance (TPM), and Just-in-Time (JIT) to optimize workflows and reduce waste; leveraging Industry 4.0 technologies for predictive maintenance and data-driven decision-making; aligning improvement efforts with strategic objectives and key performance indicators (KPIs); and proactively managing risks through early identification and mitigation of critical failure points. The proposed framework offers a practical roadmap for achieving operational efficiency, innovation, and sustainability in digitally enabled manufacturing environments. While conceptual, it lays the groundwork for future research aimed at validating and refining the model through empirical studies, pilot projects, and simulation-based evaluations.