Smart Maintenance in the Cement Industry: A Meta-Synthesis of Industry 4.0 Technologies and Applications

Document Type : Research Paper

Authors

1 M.Sc. Student of Production and Operations Management, Faculty of Industrial Management and Technology, College of Management, University of Tehran, Tehran, Iran.

2 Assistant Prof., Faculty of Industrial Management & Technology, College of Management, University of Tehran, Tehran, Iran.

3 Prof., Faculty of Industrial Management & Technology, College of Management, University of Tehran, Tehran, Iran.

4 MSc. of Supply Chain Management , Department of Logistics and Operations, Business School, HEC Montreal University, Quebec, Canada.

10.22059/imj.2026.408275.1008276

Abstract

Objective: The cement industry, vital to infrastructure and the economy, faces challenges such as high energy use, significant environmental emissions (nearly a ton per ton of cement), high costs, and unplanned downtime. Traditional maintenance methods are often inefficient and costly. Transitioning to Smart Maintenance—using Industry 4.0 data-driven, predictive, and prescriptive strategies—is essential for survival. It aims to boost efficiency, reduce costs, improve safety, and meet sustainability goals by optimizing energy and materials, making industries more resilient, agile, and future-ready, and future-proofing industrial operations. This research aims to identify, categorize, and explain key Industry 4.0 technologies and their practical applications in smart maintenance of the cement industry. It addresses a gap by providing a structured framework that links these digital technologies to specific maintenance functions, offering clarity for academia and industry in this slow-to-innovate sector.
Methodology: This study used a rigorous qualitative meta-synthesis to review and synthesize literature, conducting a protocol-driven search across Scopus and Web of Science for peer-reviewed articles from 2020 to 2025. After a multi-stage screening and quality assessment with CASP, 36 high-quality articles were selected. Through inductive coding and thematic synthesis, core technologies and applications were systematically extracted, analyzed, and categorized.
Results: The meta-synthesis identified 8 key Industry 4.0 technologies for smart maintenance, with 27 applications. These include IoT with 5 applications; Robotics and Drones with 4; and AI & Machine Learning, Digital Twin, AR/VR, Blockchain, Edge & Cloud Computing, and 3D Printing, each with 3 applications. They cover the entire maintenance lifecycle, from predictive analytics and virtual stress simulation to automated inspections, real-time monitoring, blockchain record-keeping, and 3D printing for spare parts.
Conclusion: This study provides a validated, structured framework that maps the Industry 4.0 ecosystem to smart maintenance in the cement sector. It offers a clear roadmap for stakeholders from plant managers to executives to shift from reactive to proactive, intelligent asset management. The framework guides technological investments and creates a taxonomy for further research. Future studies can explore implementation, ROI, integration, and sustainability impacts, helping the industry achieve resilience, productivity, and environmental goals.

Keywords

References

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Industrial Management Journal
Volume 18, Issue 2
2026
Pages 96-120

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