Lean maintenance 4.0: Enhancing welding machine reliability in steel galvanizing processes

Abstract

Maintenance is a critical function in the steel industry, playing a key role in production performance. Lean methodologies are extensively implemented in industrial settings, emphasizing practices that drive continuous improvement. Industry 4.0 has emerged through intelligent technologies designed to digitalize industrial processes. The combination of these approaches creates meaningful synergies that can assist both researchers and practitioners in enhancing the operational efficiency of organizational assets. The objective of this study is to investigate how Lean 4.0 principles can enhance maintenance management and operational efficiency in a welding machine within a steel galvanizing process. This research applies Lean 4.0 principles through an empirical case study of a welding machine in a steel galvanizing line, focusing on ensuring welding quality and optimizing maintenance processes. The findings reveal a considerable reduction in production downtime: by standardizing disc replacement procedures, introducing a machine checklist, and providing staff training, the continuous galvanizing line achieved a reduction of 375 minutes per year in total welding machine downtime, compared to the historical baseline of 496 minutes per year specifically associated with welding disk failures. This optimization resulted in organizational improvements and a more competitive industrial environment with skilled personnel.

Article history: Received (December 19, 2025); Revised (June 19, 2026); Accepted (July 28, 2026); Published online (October 14, 2026)