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Enrique Mora

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Why is “Autonomous Maintenance” essential?

Among the many tools in the Lean Manufacturing arsenal, Autonomous Maintenance has been identified as one of the Corner-Stones of Improved Effectiveness.

Our Autonomous Maintenance Program aims at developing an Organization-Wide culture where All associates at All levels and Areas of Responsibility discover the advantage of engaging into keeping the productive capacity of the enterprise at its optimal performance.

Important semantic equivalents between
[Lean] and “Traditional Manufacturing”…

[Associates] = “Employees”

[Areas of Responsibility] = “Depart-ments”

[Leaders] = “Supervisors and Managers”

[Leadership] = “Authority”

Team Work

The kind of Team Work concept promoted by Autonomous Maintenance promotes a higher level of cooperation among the whole population of the Enterprise. This of course produces a better culture where communication is optimized thus easing problem resolution processes. As a result, everyone gets a fulfillment feeling, which makes them happier. Quality gets a vital boost under such environment.


When everyone perceives and understands the importance and benefits of preserving the productivity in all the assets, a critical switch of mindset takes place. No longer “that is not my job” responses. Total involvement means that we all feel like, and Are the owners of our operation. At this point, we all know the answers or at least know where to find them.

Serious Training

To achieve this, the sporadic and shallow training which is usually the norm in the industry, turns into an everyday more detailed activity, in which we all are constantly learning from each other. This has been a breakthrough, since it increases our general knowledge of the business and improves our self-esteem.

Maintenance Technicians no more…

We don’t need the Maintenance Technicians any more… to take care of minor issues, so now they can devote their attention to more significant improvements in our tools, machines, and installations.  As a result, the plant has a more reliable operation, which reduces cost and improves profits.


One critical ingredient of Autonomous Maintenance is Motivation. It is necessary to make sure that we all perceive benefits from its implementation. In order to do that, leaders, operators, and technicians must receive a thorough training on the Kaizen principles. Continuous Improvement presents everyone with countless opportunities to ease our jobs and increase our results.

All this derives into a natural “Pride” for all the participants.

Our Autonomous Maintenance Program

Our program establishes a self deployment process. Once a “Pilot” team gets the initial training and motivation, and each participant experiences immediate improvements, the culture keeps strengthening and spreading through all the areas of responsibility.

Here are some of the basic components of our
Autonomous Maintenance Program:

  • The origin of most conflicts: Poor Communication

  • How can I contribute to improve it?

  • What is Kaizen?

  • Why should we participate?

  • What is in it for ME?

  • Learning, it is fun!

  • Cooperation is in our nature

  • We all need each other

  • What can I improve today?

  • How do I get others to support my project?

  • Recognition, the most valuable reward

  • The best way to earn the respect of others

  • Bringing equipment features to “Like New” or better

  • Making it easier all the time

  • What is “Maintenance?”

  • What is “Reliability?”

  • Using the right tools

  • Safety as priority number one

  • The “One Point Lessons”

  • Hands On – the best learning strategy

  • Choose a project

  • Commitment from everyone

  • The Pride of Realization

  • Taking advantage of My Resources

  • Role models

  • Behavior models

  • Continuous Improvement is That

  • What makes me valuable?

  • KPIs and my Score-Card

  • Value-added and non-value-added activities

  • Leaders required – Bosses not needed

  • Environment Choices

  • Focus on particular issues of each organization

We Can Help!

After more than 30 years serving a wide array of industries and customers, we have kept developing this program, and keep it constantly updated. It is the core component of TPM. This program is delivered in three to four days combining classroom sessions and hands-on implementation. The size of an optimal team is 6 to 10 participants. It is recommended for the team to be comprised of a balanced number of operators, technicians, administrative associates, and leaders. Genders should reflect the general population of the Enterprise.

Feel free to ask for any additional information.


TPM ConceptTPM in America Maintenance DefinitionDefinition of  Maintenance  History History of Maintenance Challenges Challenges Procedure TPM Procedure arrwbull.gif (359 bytes) What TPM is
and what it is not
arrwbull.gif (359 bytes) Setting priorities Keep Learning Team Roles &   Responsibilities A Basic - The 5 Ss The 5 S's Process Autonomous Maintenance Autonomous
Technical Advantages Technical 
Personal Attitude Improvement Personnel Attitude 
Top Management Support Top Management
It is easier than you think Implement TPM, It is Easier Than
You Thought!
Any Questions? Any suggestions? Handout for your TeamWhat is TPM? (handout) Doctor Roberts StudyDr. Roberts' Study Visual SystemsVisual Systems, High Value Resource

Other Recommended Articles:

From The Origins of Maintenance to the TPM Concept

TPM Definition and Procedure - Leadership for Success

TPM Education and Training - Self Discovery - One Point Lesson

Chronic Losses - Reliability Deterioration

TPM Optimal Operability and Root Cause Analysis

Don't Overlook the Small Loses - SMED - Setup Reduction Time

Direct Benefits of TPM in the Quality of the Product

How to Determine Plant Readiness for TPM Implementation?

Procedure for a Successful TPM Implementation Pilot Project

TPM Program Kick Off!

The Plan: Establish an Appropriate Feasible Program

The Effective Steps to Start Autonomous Maintenance

Permanent Advantages and Benefits from TPM

More Keys to Succeed in TPM Implementation

Visual Systems

CMMS - Computerized Maintenance Management Systems

OEE - Overall Equipment Effectiveness

If you find our free information useful, just imagine how much your operation will improve when we can work together
one on one!

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Total Productive Maintenance and All Lean Strategies
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This page last updated on

25 August, 2011 12:43









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