Advancing Green Industrial Systems in the Era of Industry 4.0/5.0:A Comprehensive Review and Strategic Framework

Abstract

Green Industrial Systems (GIS) embody an integrated paradigm that merges sustainable practices, advanced digital technologies, and strategic management to enhance environmental performance, resource efficiency, and socio-economic resilience. While previous research has explored clean production, circular economy models, and Industry 4.0/5.0 technologies, few studies have synthesized these dimensions into a unified GIS framework that effectively aligns technological innovation, human-centricity, and operational excellence.

This study presents a systematic literature review (SLR) of peer-reviewed publications from 2015 to 2025. Findings reveal that Industry 4.0 technologies—such as artificial intelligence (AI), the Internet of Things (IoT), blockchain, digital twins, and additive manufacturing—significantly enhance energy efficiency, predictive maintenance, waste reduction, and circular operations. In parallel, Industry 5.0 principles advance human-centric design, ethical engineering, and social value creation. Nonetheless, critical challenges persist, including fragmented integration, interoperability gaps, workforce skill deficits, high implementation costs, and inadequate sustainability metrics. Conversely, notable opportunities emerge from technological innovation, cross-sector collaboration, and circular value creation.

Drawing on these insights, the study proposes a strategic GIS framework structured around four pillars: Technological Enablement, Sustainable Operations and Circularity, Human-Centric Integration, and Governance and Policy Alignment. The framework is implemented through a five-phase roadmap—Assessment, Design, Deployment, Optimization, and Sustainability & Resilience—demonstrating how Industry 4.0/5.0 technologies can strengthen operational excellence methodologies such as Green Lean Six Sigma (GLSS). By integrating digital transformation, sustainability, and human-centric principles, the framework offers a practical pathway toward resilient, low-impact, and future-ready industrial ecosystems that foster efficiency, environmental stewardship, and long-term socio-economic value creation.