Abstract: Industry 4.0 (I4.0) has attracted significant attention in manufacturing fields, but its implementation success rate remains low, particularly among Asian countries facing barriers. This study synthesizes key challenges to I4.0 adoption in Asian manufacturing, drawing on funnel plot analysis and a systematic review of Scopus database entries to evaluate reliability and publication bias. The study’s validity is reinforced by a systematic review process, while its reliability is established through the rigorous application of funnel plot analysis to evaluate publication bias, thereby providing a comprehensive understanding of these barriers. Important barriers identified include a lack of technical skills, high implementation costs, limited IT literacy, concerns around data security, and unclear returns on investment (ROI), among others. These findings offer actionable insights for addressing I4.0 implementation challenges and support successful adoption across diverse manufacturing contexts in Asia. While some barriers receive less immediate attention, they act as underlying causes that trigger other, more critical barriers, creating a compound effect on I4.0 adoption. Exploring the interconnections among barriers through advanced analytical methods is crucial to uncovering their cascading effects and developing integrated strategies to address them. In addition, future research should include country-specific empirical studies to further understand regional variations and unique factors impacting I4.0 adoption.
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