Ownership Maintenance Transformation

Client: Toyota UK, Automotive Manufacturing Leader

Led by: Lee Bellis, GEMBEX Founding Consultant

Toyota UK led an improve machine reliability and team ownership with Lee across key production lines, including ZZ BLOCK, ZZ HEAD, ZZ CRANKSHAFT, and SZ lines.

With some equipment operating at just 40% OPR (Operational Performance Rate), the challenge was to embed Ownership Maintenance and elevate performance across the plant.

A black background with gold sparkles and the word "Objectives" written in gold in the center.

  • Implement Ownership Maintenance across all production lines

  • Increase machine OPR from 40% to 80%

  • Build internal capability through Japanese-led training and local coaching

  • Empower team members to take ownership of machine reliability

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  • Intensive Training: Completed a rigorous 6-month program with Japanese experts from the Kamigo plant, then cascaded the learning to UK managers, engineers, supervisors, and team members.

  • Ownership Maintenance Rollout: Embedded Ownership Maintenance across all ZZ and SZ lines, assigning machines to individual leaders and fostering accountability.

  • Digital Monitoring System: Implemented a computer-based KPI tracking system for every machine, enabling Ownership Leaders to monitor and manage performance in real time.

  • Maintenance Collaboration: Partnered with maintenance teams to train Ownership Leaders on resolving repetitive faults, freeing maintenance to focus on complex issues.

  • Planned Downtime Optimization: Identified and addressed machine issues during 30-minute planned downtime windows, improving responsiveness and reliability.

  • Team Empowerment: Trained members so that each Ownership Leader treated their assigned machine as their own, building pride and accountability.

A dark background with gold stars and the word 'Results' in gold text

  • Machine OPR increased from 40% to 80% across targeted lines.

  • Ownership Leaders fully engaged in machine care and performance.

  • Reduced repetitive faults and improved maintenance efficiency.

  • Real-time KPI visibility enhanced accountability and decision-making.

  • A culture of ownership and continuous improvement embedded across the plant.

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This project demonstrated the power of Ownership Maintenance as both a technical and cultural shift.
By combining deep learning from Japan with local empowerment, Toyota UK built a high-performance
environment where every team member became a steward of operational excellence.