Management and maintenance with AI

AI without rules is an intern without a boss. I build the process, the memory and the agents.

Thirty years in operations, maintenance, processes, projects and quality. Today I run my company with a team of AI agents, and I build the same for other leaders, with the decision in the hands of whoever signs off.

Rodrigo Rotondo smiling, wearing glasses and a black T-shirt
Rodrigo RotondoCMRP · 30 years in operations
30 years
operations, maintenance, processes and quality
CMRP
certified maintenance & reliability
250+
customers at Manusis4, the company I founded
23
AI agents on my digital team
Maintenance with AI · AI in practice

The problem was never the AI. It was the context it was missing.

  • 01
    Asks before it answers

    Criticality, operating regime, history. Ordinary AI guesses; the skill asks.

  • 02
    Works on your data

    A work order export from any system becomes an analysis with the assumptions in plain view.

  • 03
    Delivers in the format management reads

    Report, plan, presentation. Not generic text you have to rewrite.

  • 04
    AI recommends, people decide

    Every output flags what depends on the technical lead.

Supervisor
Here is the work order export for the last 12 months on line 2. Which assets are costing me the month?
Skill · recurring failures
Before I conclude, two questions: which asset is critical to production? Are there downtime restrictions on this line?
Supervisor
Filling is critical. Downtime only on Sundays.
Skill · recurring failures
✓ Work orders read, 3 assumptions stated.
The recirculation pump accounts for most of the corrective work: “seal leak”, “replace mech. seal” and “seal leaking” are the same failure.
Suggestion: root cause analysis with the team and a review of the preventive plan. Your call: the Sunday window.

Illustrative example, no customer data.

Maintenance second brain

Your maintenance already has a brain: your most senior technician. What's missing is the second one.

What it is. The maintenance second brain is your plant's organized memory: what the team knows about each asset, written down, connected and ready to be consulted, by people and by AI. It is not one more system. It is what makes the system you already have, and the AI you already use, answer like someone who knows the plant.

  • 01
    Assets you can trust

    Standardized hierarchy, criticality and master data. Without that, nothing connects.

  • 02
    History that explains

    A closed work order that says what was found, the cause and what was done. Not just “done”.

  • 03
    What was never written down

    Procedures, manuals, lessons learned and the bench technician's tricks, captured before retirement.

  • 04
    Everything linked

    Each failure linked to the asset, the cause, the action and the result. That link is what becomes context for the AI.

Supervisor · 2 a.m.
P-200 is vibrating again. Sam retired. What do we already know about this pump?
Second brain
✓ 2 misalignment events in 18 months, same vibration signature.
Sam's note (March work order): “check the base before you blame the coupling”.
Manual, section 4.3: cross-pattern tightening, 65 N·m.
Suggestion: laser alignment and a base check. Your call.

Illustrative example, no customer data.

Capturewhat is in the system, on paper and in the team's heads
Organizea master data and recording standard everyone follows
Connectasset, failure, cause, action and result on the same thread
ConsultAI answers with sources, and the decision stays with whoever signs off

I help build your maintenance second brain. With your team, in the system you already use: an assessment of what exists, a recording standard, capture of the knowledge that is about to walk out the door, and AI connected to consult it.

I want to build mine →
AI Maintenance Kit · waiting list

Skills for the real week of people who run maintenance.

For maintenance managers, supervisors and planners. They work in the AI you already use: Claude, ChatGPT, Copilot or Gemini.

Planning

Preventive plan per asset

● launch batch
Reliability

Recurring failures from work orders

● launch batch
Reliability

Guided root cause analysis

● launch batch
Planning

Backlog cleanup

● launch batch
Management

Monthly management report

● next batch
Shutdowns

Shutdown scope and schedule

● next batch
Materials

Critical spare parts per asset

● next batch
People

The difficult conversation with a technician

● next batch
Done. You are on the waiting list and will hear when it launches.
Free diagnostic · 10 min

Where does your maintenance still depend on luck?

Twelve questions born from a Friday with a reactor down and a bearing found too late. At the end, you see where the risk is and get the reading by email.

luckmethod
  • 01
    Where is the history of your critical asset?

    And how long does it take to rebuild it?

  • 02
    Do recurring failures show up on their own?

    Or does someone have to remember them?

  • 03
    Is the knowledge in the system?

    Or in your most senior technician's head?

Start the diagnostic
Path

From the first prompt to your plant's copilot.

Kit

Ready-made skills for the working week.

waiting list

Applied course

Failure Analysis with AI, from the data to management.

coming soon

Program

Eight live weeks, with a project in your plant.

coming soon

Mentoring

For people who lead maintenance.

Studio portrait of Rodrigo Rotondo in a black blazer
About

A maintenance engineer before becoming a CEO.

About 20 years ago, a defective bearing found by chance on a Friday, with a critical reactor almost reassembled, changed my question: the problem was not the bearing, it was the information model. Since then I have worked so that maintenance stops depending on luck.

CMRPCertified Maintenance & Reliability Professional
Manusis4Founder · more than 250 customers in Brazil and the US
SpeakerSMRP 2026 · Generative AI for Maintenance
AuthorGestão que Destrava · weekly newsletter
Quality and processesISO 9001 and ISO 14001 internal auditor
ProjectsPMI Project Management (FGV)
See my full background →
SMRP 2026 talk · English edition · free

What I think about AI in maintenance, in 55 slides.

AI amplifies the data you already have. The talk I presented at the SMRP conference follows one pump from start to finish to show what needs to be in place before AI, and how it enters planning, decision-making and failure analysis.

Slide from the talk: the real power of AI is not generating answers, it is helping people make better decisions
Every week · by email

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(Management that unlocks) Management, people and technology in maintenance. More than 3,000 subscribers. In English, in your inbox.

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Contact

Implementation, mentoring, talks or workshops.

To set up a team of agents in your area, tell me the size of the team and the task that steals the most time. Mentoring is by application. For talks and workshops, tell me the event or the team and the date. I reply personally.

Message received. I reply personally.