IDEAS home Printed from https://ideas.repec.org/a/eee/proeco/v279y2025ics0925527324003323.html

How lean and industry 4.0 affect worker outcomes and operational performance: A quantitative assessment of competing models

Author

Listed:
  • Frank, Alejandro G.
  • Sturgeon, Timothy J.
  • Benitez, Guilherme B.
  • Marodin, Giuliano A.
  • Ferreira e Cunha, Samantha

Abstract

This study explores the relationship between Lean Manufacturing and Industry 4.0, two paradigms that have shaped modern manufacturing. While Lean Manufacturing seeks to optimize sociotechnical systems by integrating workers, processes, and technologies, the focus of Industry 4.0 is to integrate digital technologies into manufacturing processes. Related literature has considered a diversity of relationships between Lean and Industry 4.0 but used contradictory models to explain their associations to operational performance. Also, while much attention has been given to the contribution of Lean and Industry 4.0 to operational performance, little is known about their effect on worker outcomes. Therefore, we aim to investigate how these two paradigms interact and their effects on both operational performance and worker outcomes. We propose competing research models – mediation and moderation – to explain plausible relationships between Lean and Industry 4.0 on worker outcomes and operational performance. We test these models through empirical analysis of survey data from 415 manufacturing companies. Our results reveal that Industry 4.0 technologies act as antecedents when they are used to enhance Lean practices for operational performance (Lean as mediator) but serve as moderators in shaping worker outcomes within Lean systems. We also examine the detailed relationships between specific Lean bundles and Industry 4.0 technologies. Our findings highlight the need to strategically balance the adoption of technologies that support Lean for operational performance improvements with technologies that modify worker activities to enhance overall worker outcomes. We contribute to reconciling different perspectives on Lean and Industry 4.0 in the design of sociotechnical manufacturing systems.

Suggested Citation

  • Frank, Alejandro G. & Sturgeon, Timothy J. & Benitez, Guilherme B. & Marodin, Giuliano A. & Ferreira e Cunha, Samantha, 2025. "How lean and industry 4.0 affect worker outcomes and operational performance: A quantitative assessment of competing models," International Journal of Production Economics, Elsevier, vol. 279(C).
    • Handle: RePEc:eee:proeco:v:279:y:2025:i:c:s0925527324003323
    DOI: 10.1016/j.ijpe.2024.109475
    as

    Download full text from publisher

    File URL: http://www.sciencedirect.com/science/article/pii/S0925527324003323
    Download Restriction: Full text for ScienceDirect subscribers only
    File URL: https://libkey.io/10.1016/j.ijpe.2024.109475?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    As the access to this document is restricted, you may want to

    for a different version of it.

    References listed on IDEAS

    as
    1. Tortorella, Guilherme Luz & Narayanamurthy, Gopalakrishnan & Thurer, Matthias, 2021. "Identifying pathways to a high-performing lean automation implementation: An empirical study in the manufacturing industry," International Journal of Production Economics, Elsevier, vol. 231(C).
    2. Andrea Furlan & Ambra Galeazzo & Adriano Paggiaro, 2019. "Organizational and Perceived Learning in the Workplace: A Multilevel Perspective on Employees’ Problem Solving," Organization Science, INFORMS, vol. 30(2), pages 280-297, March.
    3. Mohammad Shahin & F. Frank Chen & Ali Hosseinzadeh & Hamed Bouzary & Awni Shahin, 2024. "Waste reduction via image classification algorithms: beyond the human eye with an AI-based vision," International Journal of Production Research, Taylor & Francis Journals, vol. 62(9), pages 3193-3211, May.
    4. Bianco, Débora & Bueno, Adauto & Godinho Filho, Moacir & Latan, Hengky & Miller Devós Ganga, Gilberto & Frank, Alejandro G. & Chiappetta Jabbour, Charbel Jose, 2023. "The role of Industry 4.0 in developing resilience for manufacturing companies during COVID-19," International Journal of Production Economics, Elsevier, vol. 256(C).
    5. Frédéric Rosin & Pascal Forget & Samir Lamouri & Robert Pellerin, 2020. "Impacts of Industry 4.0 technologies on Lean principles," International Journal of Production Research, Taylor & Francis Journals, vol. 58(6), pages 1644-1661, March.
    6. Tortorella, Guilherme Luz & Fogliatto, Flavio S. & Cauchick-Miguel, Paulo A. & Kurnia, Sherah & Jurburg, Daniel, 2021. "Integration of Industry 4.0 technologies into Total Productive Maintenance practices," International Journal of Production Economics, Elsevier, vol. 240(C).
    7. Frank, Alejandro Germán & Dalenogare, Lucas Santos & Ayala, Néstor Fabián, 2019. "Industry 4.0 technologies: Implementation patterns in manufacturing companies," International Journal of Production Economics, Elsevier, vol. 210(C), pages 15-26.
    8. Meindl, Benjamin & Ayala, Néstor Fabián & Mendonça, Joana & Frank, Alejandro G., 2021. "The four smarts of Industry 4.0: Evolution of ten years of research and future perspectives," Technological Forecasting and Social Change, Elsevier, vol. 168(C).
    9. Tae-Yeol Kim & Jie Wang & Junsong Chen, 2018. "Mutual Trust Between Leader and Subordinate and Employee Outcomes," Journal of Business Ethics, Springer, vol. 149(4), pages 945-958, June.
    10. David Wuttke & Ankit Upadhyay & Enno Siemsen & Alexandra Wuttke-Linnemann, 2022. "Seeing the Bigger Picture? Ramping up Production with the Use of Augmented Reality," Manufacturing & Service Operations Management, INFORMS, vol. 24(4), pages 2349-2366, July.
    11. D. Bianco & A. Bueno & Moacir Godinho Filho & H. Latan & G. Miller Devós Ganga & A.G. Frank & C.J. Chiappetta Jabbour, 2023. "The Role of Industry 4.0 in Developing Resilience for Manufacturing Companies during COVID-19," Post-Print hal-04277168, HAL.
    12. Tortorella, Guilherme Luz & Saurin, Tarcísio Abreu & Filho, Moacir Godinho & Samson, Daniel & Kumar, Maneesh, 2021. "Bundles of Lean Automation practices and principles and their impact on operational performance," International Journal of Production Economics, Elsevier, vol. 235(C).
    13. Sunder M, Vijaya & Prashar, Anupama, 2024. "The interplay of lean practices and digitalization on organizational learning systems and operational performance," International Journal of Production Economics, Elsevier, vol. 270(C).
    14. Dalenogare, Lucas Santos & Benitez, Guilherme Brittes & Ayala, Néstor Fabián & Frank, Alejandro Germán, 2018. "The expected contribution of Industry 4.0 technologies for industrial performance," International Journal of Production Economics, Elsevier, vol. 204(C), pages 383-394.
    15. Guilhem Bascle, 2008. "Controlling for endogeneity with instrumental variables in strategic management research," Post-Print hal-00576795, HAL.
    16. Marodin, Giuliano & Frank, Alejandro Germán & Tortorella, Guilherme Luz & Netland, Torbjørn, 2018. "Lean product development and lean manufacturing: Testing moderation effects," International Journal of Production Economics, Elsevier, vol. 203(C), pages 301-310.
    17. Jéssica de Assis Dornelles & Néstor F. Ayala & Alejandro G. Frank, 2023. "Collaborative or substitutive robots? Effects on workers’ skills in manufacturing activities," International Journal of Production Research, Taylor & Francis Journals, vol. 61(22), pages 7922-7955, November.
    18. Matteo Rossini & Federica Costa & Guilherme Luz Tortorella & Alessia Valvo & Alberto Portioli-Staudacher, 2022. "Lean Production and Industry 4.0 integration: how Lean Automation is emerging in manufacturing industry," International Journal of Production Research, Taylor & Francis Journals, vol. 60(21), pages 6430-6450, November.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Seelent, João Felipe Capioto & Lermen, Fernando Henrique & Franco, Cíntia Wilke & Benitez, Guilherme Brittes, 2025. "Managing paradoxical tensions between Corporate Social Responsibility and Automation: How organizations reach sustainability and digital transformation," International Journal of Production Economics, Elsevier, vol. 288(C).
    2. Elnadi, Moustafa & Gheith, Mohamed Hani & Troise, Ciro & Bresciani, Stefano & Abdallah, Yasser Omar, 2025. "Examining the interplay of industry 4.0, lean, agile, and circular manufacturing practices on sustainability performance," Technovation, Elsevier, vol. 146(C).
    3. Antonius Setyadi & Suharno Pawirosumarto & Alana Damaris, 2025. "Sustainable Operations Strategy in the Age of Climate Change: Integrating Green Lean Practices into Operational Excellence," Sustainability, MDPI, vol. 17(13), pages 1-36, June.
    4. Antonius Setyadi & Suharno Pawirosumarto & Alana Damaris, 2025. "Toward a Resilient and Sustainable Supply Chain: Operational Responses to Global Disruptions in the Post-COVID-19 Era," Sustainability, MDPI, vol. 17(13), pages 1-39, July.
    5. Odohoedi Johnson O & Ayandele Isaac A & Umana Victoria S, 2025. "Lean Manufacturing Strategy and Corporate Performance of Selected Pharmaceutical Firms in Southwest Nigeria," International Journal of Research and Innovation in Social Science, International Journal of Research and Innovation in Social Science (IJRISS), vol. 9(14), pages 1420-1434, June.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Sunder M, Vijaya & Prashar, Anupama, 2024. "The interplay of lean practices and digitalization on organizational learning systems and operational performance," International Journal of Production Economics, Elsevier, vol. 270(C).
    2. Cifone, Fabiana Dafne & Hoberg, Kai & Holweg, Matthias & Staudacher, Alberto Portioli, 2021. "‘Lean 4.0’: How can digital technologies support lean practices?," International Journal of Production Economics, Elsevier, vol. 241(C).
    3. Colombari, Ruggero & Neirotti, Paolo & Berbegal-Mirabent, Jasmina, 2024. "Disentangling the socio-technical impacts of digitalization: What changes for shop-floor decision-makers?," International Journal of Production Economics, Elsevier, vol. 276(C).
    4. Xi, Mengjie & Liu, Yang & Fang, Wei & Feng, Taiwen, 2024. "Intelligent manufacturing for strengthening operational resilience during the COVID-19 pandemic: A dynamic capability theory perspective," International Journal of Production Economics, Elsevier, vol. 267(C).
    5. Bokhorst, Jos A.C. & Knol, Wilfred & Slomp, Jannes & Bortolotti, Thomas, 2022. "Assessing to what extent smart manufacturing builds on lean principles," International Journal of Production Economics, Elsevier, vol. 253(C).
    6. Nakandala, Dilupa & Elias, Arun & Hurriyet, Hilal, 2024. "The role of lean, agility and learning ambidexterity in Industry 4.0 implementations," Technological Forecasting and Social Change, Elsevier, vol. 206(C).
    7. Tortorella, Guilherme Luz & Saurin, Tarcisio A. & Hines, Peter & Antony, Jiju & Samson, Daniel, 2023. "Myths and facts of industry 4.0," International Journal of Production Economics, Elsevier, vol. 255(C).
    8. Bueno, Adauto & Godinho Filho, Moacir & Cecconello, Moiseis & de Santa-Eulália, Luis Antonio & Caiado, Rodrigo Goyannes Gusmão & Ganga, Gilberto Miller Devós & Carvalho, João Vidal, 2025. "Advancing towards industry 4.0: A maturity model for smart shop floor control," International Journal of Production Economics, Elsevier, vol. 282(C).
    9. Bianco, Débora & Bueno, Adauto & Godinho Filho, Moacir & Latan, Hengky & Miller Devós Ganga, Gilberto & Frank, Alejandro G. & Chiappetta Jabbour, Charbel Jose, 2023. "The role of Industry 4.0 in developing resilience for manufacturing companies during COVID-19," International Journal of Production Economics, Elsevier, vol. 256(C).
    10. Govindan, Kannan, 2025. "Analyzing the dynamic capabilities of emerging technologies for industrial emergency situations," International Journal of Production Economics, Elsevier, vol. 281(C).
    11. A. H. M. Yeaseen Chowdhury & M. M. Hussain Shahadat & Saurav Chandra Talukder & Arnold Csonka & Maria Fekete Farkas, 2025. "Integrating CRM, Lean Practices, and Use of IT to Enhance Operational Performance: The Mediating Role of Quality Information Sharing," Logistics, MDPI, vol. 9(3), pages 1-25, September.
    12. Kerstens, Kristiaan & Azadi, Majid & Kazemi Matin, Reza & Farzipoor Saen, Reza, 2024. "Double hedonic price-characteristics frontier estimation for IoT service providers in the industry 5.0 era: A nonconvex perspective accommodating ratios," European Journal of Operational Research, Elsevier, vol. 319(1), pages 222-233.
    13. Marcon, Érico & Le Dain, Marie-Anne & Frank, Alejandro G., 2022. "Designing business models for Industry 4.0 technologies provision: Changes in business dimensions through digital transformation," Technological Forecasting and Social Change, Elsevier, vol. 185(C).
    14. Oliveira-Dias, Diéssica de & Maqueira-Marin, Juan Manuel & Moyano-Fuentes, José & Carvalho, Helena, 2023. "Implications of using Industry 4.0 base technologies for lean and agile supply chains and performance," International Journal of Production Economics, Elsevier, vol. 262(C).
    15. Benitez, Guilherme Brittes & Ghezzi, Antonio & Frank, Alejandro G., 2023. "When technologies become Industry 4.0 platforms: Defining the role of digital technologies through a boundary-spanning perspective," International Journal of Production Economics, Elsevier, vol. 260(C).
    16. Benitez, Guilherme Brittes & Ayala, Néstor Fabián & Frank, Alejandro G., 2020. "Industry 4.0 innovation ecosystems: An evolutionary perspective on value cocreation," International Journal of Production Economics, Elsevier, vol. 228(C).
    17. Laubengaier, Désirée A. & Cagliano, Raffaella & Canterino, Filomena, 2022. "It Takes Two to Tango: Analyzing the Relationship between Technological and Administrative Process Innovations in Industry 4.0," Technological Forecasting and Social Change, Elsevier, vol. 180(C).
    18. Seelent, João Felipe Capioto & Lermen, Fernando Henrique & Franco, Cíntia Wilke & Benitez, Guilherme Brittes, 2025. "Managing paradoxical tensions between Corporate Social Responsibility and Automation: How organizations reach sustainability and digital transformation," International Journal of Production Economics, Elsevier, vol. 288(C).
    19. Culot, Giovanna & Orzes, Guido & Sartor, Marco & Nassimbeni, Guido, 2020. "The future of manufacturing: A Delphi-based scenario analysis on Industry 4.0," Technological Forecasting and Social Change, Elsevier, vol. 157(C).
    20. Kai, Dalton Alexandre & Pinheiro de Lima, Edson & Benitez, Guilherme Brittes, 2024. "A social cognitive perspective in innovation ecosystems: Understanding startups from ideation to consolidation in industry 4.0 era," Technological Forecasting and Social Change, Elsevier, vol. 209(C).

    More about this item

    Keywords

    ;
    ;
    ;
    ;
    ;
    ;

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:eee:proeco:v:279:y:2025:i:c:s0925527324003323. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Catherine Liu (email available below). General contact details of provider: http://www.elsevier.com/locate/ijpe .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.