Smart Factories, Smarter Research: A Critical Review of Manufacturing 4.0 Technologies, Sustainability, and the Road to Industry 5.0

Abstract

Industry 4.0 has produced one of the fastest-growing bodies of engineering and management research; much of this output remains siloed by technology domain. This study addresses that fragmentation through a structured critical review (a review-of-reviews), synthesising 70 peer-reviewed review articles and foundational sources (2003–2026) spanning 14 technology domains. The review introduces the I4.0-STS framework, an original four-layer structure organising evidence across physical, cyber, cognitive, and socio-organisational dimensions. Five principal findings emerge. The physical and cyber layers show consistent evidence of maturity. Industry-reported lighthouse IIoT deployments show 20–30% energy and up to 39% lead-time reductions. AI-driven predictive maintenance shows 30–50% unplanned-downtime reductions. The cognitive layer (LLM-augmented digital twins and generative AI interfaces) is technically feasible but outpaces its governance frameworks. Cybersecurity remains insufficiently governed, with documented ransomware incidents in manufacturing OT environments underscoring the risks of OT–IT convergence. SME adoption and developing-economy manufacturing transformation remain comparatively under-addressed. Finally, 12 research gaps are assessed as of June 2026, five rated Open, with future research directions proposed for each, framed against the emerging Industry 5.0 agenda. All findings are second-order interpretations from the source reviews, and their limitations are stated explicitly.