Optimizing maintenance strategies in smart manufacturing: a systematic review of lean practices, total productive maintenance (TPM), and digital reliability
Abstract
This systematic review investigates the integration of Lean practices, Total Productive Maintenance (TPM), and digital reliability strategies to optimize maintenance operations in the context of smart manufacturing ecosystems. Drawing upon a comprehensive analysis of 96 peer-reviewed studies published between 2015 and 2024, the review rigorously follows the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines to ensure transparency, methodological rigor, and replicability. The review critically examines how traditional maintenance frameworks—namely Lean Maintenance, which focuses on waste elimination, continuous improvement, and process standardization, and TPM, which emphasizes proactive and preventive maintenance through deep operator involvement—interact with advanced digital reliability approaches. These digital techniques include predictive analytics, IoT-enabled condition monitoring, artificial intelligence-driven diagnostics, and digital twin technologies, which collectively enable real-time fault detection, predictive failure forecasting, and data-informed decision-making. The synthesis reveals that hybrid maintenance models combining Lean, TPM, and digital reliability tools consistently deliver superior outcomes, such as substantial reductions in unplanned downtime, enhanced asset utilization rates, increased Overall Equipment Effectiveness (OEE), and greater agility in production planning and scheduling. The review also highlights…
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Evidence Hub reads this as a systematic review. Its evidence level is 1 of 5 (Highest · pooled evidence). Pooled evidence from several studies sits at the top of the evidence pyramid.
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