<p>This study investigates the integration and implementation of Lean Manufacturing and Industry 4.0 technologies within Indian fabrication industries, addressing the challenges of adopting "Lean 4.0." It highlights significant barriers, including insufficient knowledge, long payback periods, and technological readiness. Utilizing a comprehensive literature review and a structured survey distributed to 500 industry professionals across southern India, the study employs statistical tools to analyze responses and rank barriers based on their impact. The research identifies critical factors such as leadership commitment, digital infrastructure, and workforce skills as pivotal for successful Lean 4.0 adoption. By leveraging descriptive statistics, correlation analysis, and regression modeling, the study provides actionable insights to policymakers and stakeholders. It underscores the need for targeted training, strategic planning, and organizational alignment to overcome integration barriers. This study bridges the gap between Lean principles and Industry 4.0, offering a pathway for improved productivity, resource efficiency, and sustainability in the manufacturing sector. The findings serve as a foundation for advancing hybrid manufacturing models, fostering innovation, and aligning with global industrial practices.</p> Graphical abstract <p></p>