Abstract

Manufacturing operations management continuously strives for competitiveness and adaptability. While Lean 4.0 primarily leveraged digitalization for efficiency gains, this paper addresses the critical research gap concerning the lack of a prescriptive, normative conceptual model capable of structurally aligning Lean principles with the three core tenets of Industry 5.0: human-centric, resilience and sustainability. A theory-building approach utilizing systematic conceptual analysis and the axiomatic design methodology was employed. This methodology maps conventional Lean principles against the Industry 5.0 pillars, enabling the derivation of a novel, multidimensional framework: the Lean 5.0 parameter integration matrix. This matrix formalizes design using the axiomatic design independence axiom, providing a mathematical basis to decouple conflicting efficiency and human-centric goals. The paper details the operational mechanisms for key Lean 5.0 tools that utilize advanced technologies like explainable artificial intelligence and collaborative robotics to achieve normative Industry 5.0 outcomes. The framework's effectiveness is validated through an empirical case study in an additive manufacturing environment. The quantitative results demonstrate that implementing the Lean 5.0 parameter integration matrix successfully resolved a critical design contradiction, leading to a 77% reduction in mean time to recovery and a 74% reduction in setup error rate, all while maintaining or slightly improving overall operational efficiency. The Lean 5.0 parameter integration matrix provides the essential structural framework for the next generation of human-centric, resilient and sustainability manufacturing.

Key words: Human-Centric, Industry 5.0, Lean 5.0, Lean Manufacturing, Sustainability, Resilience.