Industry 4.0 adoption surges but integration gaps threaten global supply chains

The review shows that Industry 4.0 has become vital to supply chain innovation, driving advances in visibility, predictive analytics, traceability, risk management and operational resilience. At the same time, the authors identify persistent adoption barriers, gaps in empirical evidence and a shortage of research exploring how companies orchestrate digital technologies across production networks. They warn that without deeper insight into integration, Industry 4.0 could fall short of its promise to deliver resilient, agile and sustainable supply chains.

Digital technologies are reshaping global manufacturing at a rapid pace, but a new large-scale academic review warns that despite accelerating adoption, companies still lack the frameworks, organizational structures and empirical insights needed to integrate Industry 4.0 tools effectively. The study finds that while research output has risen sharply since 2019, most work focuses on adoption models rather than on-the-ground integration, leaving crucial questions about readiness, context and long-term transformation unanswered.

The paper, “Supply Chain in the Age of Industry 4.0: A Literature Review,” published in Logistics, is based on 405 publications between 2016 and 2025. The authors conduct a detailed bibliometric mapping and systematic review of empirical studies to identify how manufacturing supply chains are evolving under the rise of IoT, AI, blockchain, big data analytics and cyber–physical systems. Their findings reveal that academic work has expanded significantly across continents, but remains heavily fragmented, with limited collaboration between research groups and a lack of real-world integration studies.

The review shows that Industry 4.0 has become vital to supply chain innovation, driving advances in visibility, predictive analytics, traceability, risk management and operational resilience. At the same time, the authors identify persistent adoption barriers, gaps in empirical evidence and a shortage of research exploring how companies orchestrate digital technologies across production networks. They warn that without deeper insight into integration, Industry 4.0 could fall short of its promise to deliver resilient, agile and sustainable supply chains.

Industry 4.0 adoption surges as global research activity expands

The study shows that research on Industry 4.0 in manufacturing supply chains has grown steadily over the last decade, with a pronounced spike after 2019. Academic output rose sharply as companies grappled with rising pressure to modernize manufacturing operations, improve supply chain visibility and respond to disruptions with real-time decision-making. The authors’ analysis of 405 publications across multiple regions reveals that India leads global research efforts, contributing more than 120 articles, followed by Italy, the United Kingdom, the United States, China and Pakistan. The geographical distribution suggests widespread recognition of the strategic importance of digital transformation.

The authors identify 159 journals contributing to the field, with high-impact publications such as the Journal of Cleaner Production, International Journal of Production Economics and Technological Forecasting and Social Change serving as the primary research outlets. The h-index distribution shows a concentration of influential studies in fields related to manufacturing performance, operations research and digital innovation, reflecting the cross-disciplinary nature of Industry 4.0.

Thematic mapping from the bibliometric analysis highlights five major research clusters. The first is supply chain optimization and resilience, where big data, predictive analytics and circular economy strategies dominate. The second cluster focuses on IoT and digital twins as drivers of smart manufacturing. The third cluster covers digital transformation, blockchain and augmented reality in industrial systems. The fourth cluster centers on frameworks, management systems and optimization models. The fifth focuses on adoption barriers, readiness assessments and maturity models, especially in emerging markets.

Collectively, these clusters reveal that Industry 4.0 research is broadening but still lacks integration across organizational, technological and environmental domains. The authors note a lack of collaboration between research groups and significant fragmentation, with many studies operating in isolation. While the volume of research is increasing, the intellectual structure remains uneven, limiting the formation of unified theories.

Empirical evidence reveals heavy reliance on adoption models but little on integration

The authors conduct a systematic literature review of 28 empirical investigations examining how manufacturing companies adopt Industry 4.0 technologies. They found that 27 of these studies rely solely on quantitative methods using questionnaires, while only one uses semi-structured interviews. This heavy preference for quantitative work limits the field’s ability to capture detailed organizational processes or contextual factors that shape digital transformation.

The researchers identify the most commonly used theoretical models in empirical studies. The Resource-Based View (RBV) is the most prevalent, appearing in seven studies, followed by the Dynamic Capabilities View (DCV) in four studies. These strategic models are used to analyze how companies leverage digital technologies as resources and how they adapt their capabilities in fast-changing environments.

Technology adoption models also feature prominently. The Technology Acceptance Model (TAM), Technology–Organization–Environment framework (TOE), Institutional Theory (INT), Diffusion of Innovation (DOI) and Behavioral Reasoning Theory (BRT) are applied to understand user perceptions, organizational readiness and external pressures. These frameworks illuminate factors shaping adoption decisions, such as perceived usefulness, ease of use, technological competence, competitive pressures, regulatory forces and organizational culture.

While these models help explain why companies adopt Industry 4.0 technologies, the review notes that few studies examine the actual processes of integration inside organizations. Most research assesses adoption intention, rather than operational alignment, implementation phases or cross-technology coordination. The authors argue that Industry 4.0 demands systemic thinking, yet current empirical evidence is dominated by surveys that capture attitudes rather than behaviors.

The study also highlights that many empirical works investigate technology in isolation, such as additive manufacturing, blockchain or IoT, leaving little insight into how multiple technologies interact. This gap is particularly concerning because Industry 4.0 transformation requires interconnected systems that integrate data flows, analytics, automation and decision-making tools.

The authors call for much more qualitative or mixed-methods research to explore how companies redesign workflows, restructure management practices, strengthen digital skills and address interoperability challenges during digital transformation.

Integration challenges remain underexplored

The review consolidates findings across empirical studies to identify adoption drivers, enabling factors and impacts of Industry 4.0 technologies on manufacturing supply chains. Across the studies, operational performance emerges as the strongest adoption driver. Companies adopt digital tools to improve productivity, reduce process inefficiencies, streamline operations and enhance decision-making through real-time data. Many studies show that big data analytics and AI yield measurable improvements in operational outcomes.

Supply chain resilience is another major driver. Firms adopt digital technologies to mitigate risk, strengthen visibility, improve traceability and respond faster to disruptions. Blockchain, IoT and analytics tools play a central role in supporting transparency and agile decision-making. Flexibility also emerges as a driver, with companies seeking technologies that allow them to adapt quickly to demand shifts or production changes.

To complement these drivers, the authors identify several enablers critical for successful adoption. Technological enablers include robust IT infrastructure, digital capabilities and system readiness. Organizational enablers include leadership commitment, a supportive culture, employee competencies and high-quality human capital. Environmental enablers include competitive pressures and strong R&D intensity.

However, the review notes that most studies stop at identifying drivers and enablers—very few examine how companies navigate integration barriers or coordinate technologies across supply chains. Challenges such as legacy systems, interoperability limitations, workforce skill gaps, investment costs and resistance to organizational change are mentioned in existing studies but not explored in detail.

The authors warn that without deeper insight into these integration challenges, many firms risk incomplete or misaligned digital transformation efforts. They emphasize that Industry 4.0 implementation is not merely about adopting individual technologies but building interconnected, strategically orchestrated digital systems that enhance performance across the supply chain.

They also note that while the literature reflects rising global interest, research in developing regions remains limited, particularly in Africa, parts of Asia and Latin America. This imbalance means that global knowledge may not accurately reflect regional readiness, contextual barriers or economic constraints.