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In the recent trend, many manufacturing industries are looking to develop and optimise their operational excellence to match the raising complexity of integrating lean concept and Industrial 4.0 (I4.0). Through literatures of previous researchers, the authors can state that the lean principle and concept are the backbone for the industrial operational excellence which has been the primary objective across all sectors. Industry 4.0 has numerous technologies advanced to back up the process optimisation and supplement need for greener environment in industries. In this chapter, the study primarily focusses on exploring and identifying the best suited Industry 4.0 technologies, which can enhance lean and green paradigms in industry through which a clear pathway can be created for smooth transfer of technology within a system. Also, the authors have discussed the enhancement of lean tools by application of Industry 4.0 technologies and have developed a relationship matrix between Industrial 4.0 technologies and lean practices.

In today’s industrial scenarios, having continuous improvement to increase the process efficiency is one of the key measures. Especially manufacturing and automotive industries are putting forth a lot of resource and time to improve the efficiency of the process without compromising the current production capacity and improve the quality rate. This paper deals with a case study of retrofitting a two-way chuck in a vertical lathe machine and thereby calculating the overall equipment effectiveness of the entire automated process in piston manufacturing. The current automated production line of piston manufacturing is being analysed with the help of value stream mapping (VSM). Value stream mapping is widely used by the industrial persons to identify the wastes i.e., non-value-added time in the process line. The Critical to Quality (CTQ) parameters in an efficient production line such as lead time, value added time, transfer time and takt time have taken into account for identifying the places of improvement. A new retrofitted design has been suggested which can increase the production efficiency of the current system with effective utilization of available resources. After implementing the modified retrofit design, the subsequent changes in the process line have also been stated through Future state VSM, which clearly indicates the reduction in drop to drop time between the cells which has been considered as the non value added time in the current system. Studies like these shows that effective utilisation of available resources through retrofitting can greatly assist the manufacturers to reduce their cost of additional investment and be sustainable among the growing competitors in the market.