This case study investigates Hero MotoCorp’s Total Productive Maintenance (TPM) initiative and its impact on productivity, quality, cost efficiency, and safety. Implemented between 2008 and 2012, the structured improvement program helped the world’s largest two-wheeler manufacturer overcome operational bottlenecks and maintenance inefficiencies. Monthly production volume rose from 78,442 to 232,200 units, while Overall Equipment Effectiveness (OEE) improved from 63% to 85% (Sharma et al., 2018). Customer complaints dropped by 84%, workplace accidents were fully eliminated, and operational costs were reduced by 19% (Matope et al., 2022). Additionally, on-time delivery improved from 75% to 96%, and kaizen suggestions increased from 320 to 6,042 per year, signaling strong employee engagement (Murthy et al., 2021). This study presents real-world data from Hero MotoCorp to illustrate how a holistic application of Lean and TPM principles can drive measurable improvements across multiple dimensions of industrial performance.