Factory 4.0: examples and levers for action

salome@merca.team

Update
July 29, 2025

Reading
2 minutes

Things to remember

- Several manufacturers have already embarked on this process. Without a big bang, but with real results.

- A factory 4.0It's an organization capable of producing faster, more serenely, with committed teams and simple digital tools.

- These are concrete practices: adaptive planning, digital job instructions, skills and empowerment tracking, HR/production cockpit.

- The objective is clear: greater reactivity, less dependence on informality, greater control over know-how in the field.

I. What is Plant 4.0?

The term is often overused. For some, a 4.0 factory means AI and robots everywhere. In practice, it's all about :

Accessible digital field tools
Better use of available data (skillsproductivity, absences, training)
A more agile organization in the face of production contingencies
Teams able to upgrade skills more quickly

Factory 4.0 is based on operations. Not a fad.

II. Why anticipate the transition to Factory 4.0?

Lines are shorter, production rates more variable: teams and tools have to be adapted continuously.
Staff turnover is increasing, and knowledge is waning: we can no longer afford to "cross our fingers" that the right skill will be there at the right time.
Products change fast, traceability is scrutinized: a rigid organization becomes a handicap.
It's often the field teams themselves who point to the need for simpler, clearer, more reliable tools.

The challenge is not to go fast, but not to wait for irritants to become blocking factors.

🎯 Download our free Excel skills matrix

III. Four concrete pillars of Factory 4.0

1. Skills and authorizations

No more long Excel files
Example: Valrhona (see the use case), which has digitized skills tracking for better team planning
Gains: real-time visibility, improved compliance, less managerial stress

2. Dynamic planning

No need to redo schedules for every absence or unforeseen event
Example: LVMH (Beauvais - France) see the use case) uses visual multi-workshop scheduling to manage 90 temps/week
Benefits: fewer errors, faster adaptation, no unanticipated line stoppages

3. Digital postage instructions

One-stop shop for critical know-how
Faster training for new recruits and better continuity
No more misplaced paper books or post-its

4. Steering HR / Production connected

Consolidated view for HR, managers, team leaders
Operational cockpit: who does what, where, at what level?
Better responsiveness in the field

IV. How to start your 4.0 transition without complexity

Map your skills with a simple template (downloadable)
Deploy a digital versatility chart with real-time views
Standardize your instructions and make them available online
Connect everything in a unified cockpit (skills x planning x training)

Mercateam deploys this in just a few weeks, based on your business repositories and real-life constraints.

🎯 Request a free demo of Mercateam software

What is Industry 4.0?

Industry 4.0, also known as the "industry of the future" or the "fourth industrial revolution", refers to the integration of intelligent digital technologies into production and industrial processes. It is based on the convergence of the virtual and physical worlds through IoT, artificial intelligence, Big Data, robotics and automation.
Beyond technology, Industry 4.0 is transforming the way work is organized: it aims for more flexible, personalized and efficient production, while raising major human, social and environmental issues, in particular employee skills development and the place of people in the factories of tomorrow.

How is Industry 4.0 transforming tomorrow's workforce?

It makes teams more versatile and autonomous, thanks to the digitization of skills and job instructions. Employees learn faster, develop new expertise and enjoy greater visibility of their role. This reduces operational stress and encourages continuous skills upgrading.

Why is the transition to Factory 4.0 essential?

Production cycles are becoming shorter and shorter, products are evolving rapidly and traceability is becoming critical. A rigid organization slows down performance, whereas a factory 4.0 enables resources and skills to be adapted in real time.