Accelerating Operational Excellence through Industry 4.0 Technologies

Abstract

While Industry 4.0 (I4.0) primarily focuses on technological advancements, Operational Excellence (OpEx) harnesses human potential. However, a critical challenge arises from the lack of integration between the two, posing a barrier to realizing the full potential of I4.0. This thesis aims to explore how to integrate I4.0 with OpEx effectively—referred to as OpEx 4.0—and to create a framework capable of measuring the maturity level of OpEx 4.0 across various organizations. Utilizing an iterative process, the framework was developed in seven steps through a multi-method approach: a thematic analysis of three existing frameworks, a semistructured literature review, and ten case studies using a Structured-case research cycle. The framework was evaluated through survey responses and maturity level analysis from six assessments across diverse organizations. Findings indicate the framework’s user-friendliness, efficiency, and reliability in generating actionable insights applicable to organizations of varying sizes, industries, and maturity levels. It enables the creation of tailored road-maps and strategic positioning relative to industry benchmarks within a quick, three-hour format per company visit, showcasing its practical applicability. Subsequently, the results informed the identification of primary challenges, opportunities, and ambitions within the Nordic manufacturing industry. The findings indicate an average OpEx 4.0 maturity rating of 2.8 out of 5, highlighting areas for improvement. Analysis reveals that companies in this sector must focus on enhancing structured improvement processes, technology utilization, comprehensive understanding of all organizational dimensions, and active employee engagement in OpEx 4.0 principles. While most organizations acknowledge the potential for improvement, there appears to be a hesitancy to actively pursue the highest maturity level of OpEx 4.0 among the vast majority of organizations