SCALING SMART MANUFACTURING FROM INDUSTRY 4.0 PILOTS TO INDUSTRY 5.0 SYSTEMS: A STRUCTURED CRITICAL REVIEW

Abstract

Many manufacturing companies can demonstrate that a digital solution works in one limited setting, yet extending it to another line, product or plant remains difficult. This paper reviews the main engineering and management conditions that influence this transition and discusses how Industry 5.0 changes the way results should be evaluated. The study is based on a structured critical review of 30 peer-reviewed articles and four institutional or standards sources. The sources were examined in relation to the implementation stage, technical and organizational requirements, and reported outcomes. The review suggests that scaling depends on several connected conditions, including stable processes, usable data, interoperable architecture, cybersecurity, clear ownership, employee involvement and lifecycle measurement. Based on these findings, the paper develops the Engineering-Management-Digitalization Scaling (EMD-S) framework. It organizes the transition from problem definition to wider deployment into six decision stages supported by four continuous controls. The framework is intended as a practical structure for discussion and decision-making, not as a maturity score or certification model. Because it is derived from literature rather than tested in a company, it should be treated as a conceptual proposal that requires empirical validation. Even with this limitation, it may help industrial managers identify why pilots stop and what evidence is needed before replication.