Integrating Industry 4.0 Technologies and Maintenance 4.0 for Sustainable Manufacturing: A Systematic Literature Review

The integration of Industry 4.0 (I4.0) technologies with Maintenance 4.0 (M4.0) practices holds strong potential for advancing sustainable manufacturing (SM). While these technologies promise improvements in resource efficiency, waste reduction, and alignment with sustainability objectives, research on their synergistic implementation remains limited. This study addresses this gap through a Systematic Literature Review (SLR) of 75 peer-reviewed papers published between 2015 and 2024, conducted in accordance with PRISMA guidelines. The review explores how I4.0–M4.0 synergy contributes to sustainability across four interconnected dimensions: economic, environmental, social, and technological. Findings show that integrating technologies such as the Internet of Things and Artificial Intelligence into maintenance operations can reduce downtime by 20–50% and enhance efficiency and system resilience by 10–25%, particularly in industries like automotive and aerospace. Digital twin technologies extend equipment lifespan by 10–25%, thereby deferring capital expenditures. Furthermore, blockchain and augmented reality improve operational transparency by 30–40%, while big data analytics and cyber-physical systems contribute to energy savings of 12–18% and reduce material waste by 20–25% through real-time quality monitoring. Despite these benefits, several challenges hinder integration, including technical barriers (e.g., legacy systems, cybersecurity risks), organizational resistance (e.g., high costs, cultural inertia), and human-related issues (e.g., skills shortages, workforce restructuring). To address these barriers, the paper proposes a holistic architecture that aligns I4.0–M4.0 integration with sustainability goals, bridging technological innovation with responsible resource management. This framework offers actionable insights for stakeholders, policymakers, and industry leaders aiming to foster resilient, efficient, and socially responsible manufacturing ecosystems.