Industry 4.0 (I4.0) is challenging for organizations, as workers lack digital competencies, and research on new roles is limited. Additionally, existing models for its adoption focus on technology incorporation, process improvement, and organizational transformation. Therefore, the opportunity exists for designing a new model that emphasizes developing employees’ competencies. A systematic literature review was conducted regarding existing models for I4.0 adoption and the desired worker competencies. After examining the gap in the current models and the categorization of their main elements, a new maturity model (MM) for I4.0 adoption, based on the development of employees’ competencies, is proposed. The MM helps practitioners and researchers assess an organization’s I4.0 adoption level in order to improve future actions. A validation process for the MM was implemented through the Delphi method. Additionally, a roadmap to guide workforce development is presented, which considers the digital challenges face by employees in advancing a strategic I4.0 adoption. The proposed roadmap allows for depicting new deployment strategies aligned with digital trends and employees’ commitments to sustaining the implementation efforts. This research recognizes talent, organizational culture, and communication plans as key elements for defining actions for developing the skills and competencies required for embracing the I4.0 enabling technologies.

This paper proposes a maturity model (MM) to become a smart organization considering Lean as a key enabler to drive I4.0 adoption. A systematic literature review on I4.0 and Lean concepts plus I4.0 adoption models was conducted through the PRISMA method based on articles from Scopus and Web of Science databases, and records from official websites (e.g., consulting firms) published between 2011 and 2022. Identifying the Lean and I4.0 relationship and comparing the models’ relevant characteristics allowed the development of the MM proposal. Although previous research refers to Lean and I4.0 collaboration, the opportunity to design a reference model for adopting both approaches was identified since their interaction enhances value creation. The comprehensive model supports structuring the types of Lean principles/methods/tools and I4.0 technologies and their action to link them and define which of them need to be implemented according to the maturity level chronologically. Additionally, the proposed MM provides an adoption roadmap that starts eliminating non-added activities in the initial stages for process improvement to integrate I4.0 enabling technologies later. The model makes it possible for practitioners to generate implementation and development processes oriented toward I4.0 adoption based on maturity levels in which Lean has the starting point at the first ones. Hence, it defines the enabling technologies to be incorporated and linked throughout the value chain, enhancing a Lean culture. This model will help organizations to become “smart” by allowing them to transition toward the best technology investment and continuously add value to their processes, people, and products. Moreover, the results will motivate researchers to study further the application of models for I4.0 adoption in which Lean is integrated to fill the gap with the I4.0 embrace caused by quickly changing industrial environments and the uncertainty and unknowledge of guidelines associated with incorporating new technologies.