Digitale Transformation als Treiber für Operational Excellence: Entwicklung einer Methodik zur Integration von Industrie 4.0 im Shopfloor Management

Abstract

To meet the demands of modern markets, manufacturing companies must make their processes increasingly flexible, efficient, and transparent. Industry 4.0 offers significant opportunities in this regard by digitally connecting machines, products, and people. This digital integration creates intelligent production systems capable of responding more quickly to changes and enabling data-driven decision-making. However, the path to Industry 4.0 is often challenging, as many companies lack clear strategies for integrating digital technologies into existing lean management structures. Against this backdrop, this thesis examines practical approaches for integrating Industry 4.0 into shopfloor management and develops concrete recommendations to support companies in their digital transformation efforts. The thesis is structured into four main chapters, each providing a comprehensive analysis of the impact of Industry 4.0 on shopfloor management. Chapter 1 outlines the research problem and objectives of the study. Chapter 2 focuses on the technological foundations of Industry 4.0, covering key technologies such as the Internet of Things (IoT), cyber-physical systems (CPS), artificial intelligence (AI), cloud and edge computing, and big data and analytics. Chapter 3 explains the principles of shopfloor management, including established lean methods such as the Toyota Production System, Kaizen, and the PDCA cycle. The core of the thesis is presented in Chapter 4, which examines the practical application of digital technologies in shopfloor management. This includes concepts like Shopfloor 4.0, Lean 4.0, Key Performance Indicator (KPI) Management 4.0, and Leadership 4.0. The methodological foundation of the thesis is based on an extensive literature review, which considers recent academic studies and specifically identifies existing research gaps and practical examples. The master thesis reveals that successfully integrating Industry 4.0 into shopfloor management requires a close alignment of technology, organization, and people. Key success factors include data-driven decision-making, real-time transparency, and adaptive process control. Companies that consistently combine lean principles with digital technologies can achieve significant efficiency gains, shorter lead times, and higher process quality. Additionally, the master thesis highlights the importance of participative management approaches and continuous improvement for the long-term success of digital solutions. The developed recommendations provide companies with practical guidance on how to implement digital transformation in shopfloor management in a structured and futureproof manner.

Date of Award	2025
Original language	German (Austria)
Supervisor	Josef Wolfartsberger (Supervisor)