Benchmarking human, digital and green performance: a novel adaptive Total Productive Maintenance 5.0 maturity framework

Purpose This article proposes a benchmarking-oriented Total Productive Maintenance 5.0 (TPM5.0) maturity framework that jointly assesses human, digital and green (HDG) performance across all eight TPM pillars in the Industry 5.0 (I5.0) era, enabling peer-referenced maturity assessment across heterogeneous firms and industrial contexts. Design/methodology/approach Semi-structured interviews with companies, triangulated with a systematic literature review, informed an HDG–TPM questionnaire. The tool is operationalised into a scoring model that treats maturity as a multidimensional, peer-benchmarking problem, computed via a Multi-Attributive Border Approximation Area Comparison-based scheme advanced with sector-size normalisation and a context-aware weighting architecture. Explainable AI and natural language processing of qualitative comments enhance transparency and support periodic updating. Findings The framework produces HDG- and pillar-level maturity profiles, assigns firms to discrete maturity classes and quantifies deviations from sector–size benchmarks. A Food-Small illustrative case demonstrates how misalignments are detected and translated into prioritised improvement actions on specific TPM pillars and HDG practices. Research limitations/implications This pilot study covers a limited set of firms within a single sector-size cluster. Future work will expand the sample to test reliability and validity, enable longitudinal analysis and support framework updates. Originality/value The study introduces the first TPM5.0 maturity model that operationalises HDG benchmarking through an adaptive, context-aware weighting logic, extending TPM, Lean and operations benchmarking literature. The framework provides a practically deployable diagnostic tool that connects peer-referenced maturity gaps to coordinated HDG improvement priorities under an I5.0 lens.