In today’s competitive manufacturing landscape, operational efficiency and machine reliability are more important than ever. But what exactly is autonomous maintenance, why should you implement it, and how can you successfully get started? This blog will walk you through everything you need to know – and more – breaking it down into seven practical steps to implement autonomous maintenance in your facility.
What is autonomous maintenance?
Autonomous maintenance is a foundational pillar of Total Productive Maintenance (TPM) that involves training and empowering machine operators to perform basic maintenance tasks. This can be tasks for cleaning, lubrication, inspection, and minor adjustments. The key idea is that operators, who work closest to the equipment, are best positioned to spot abnormalities early and prevent equipment deterioration. Instead of relying solely on maintenance specialists for routine upkeep, autonomous maintenance decentralizes these responsibilities, turning operators into the first line of defence against machine failure. This not only helps detect issues earlier but also fosters a culture of ownership and continuous improvement on the shop floor.
Why should you implement autonomous maintenance?
By implementing autonomous maintenance, a bunch of benefits will come your way. This can be tangible or intangible benefits, such as:
- Reduced downtime: Operators can identify and address small issues before they escalate into costly breakdowns.
- Improved equipment lifespan: Regular cleaning and lubrication prevent premature wear and tear.
- Higher quality: Well-maintained equipment ensures consistent product quality by avoiding process disruptions.
- Cost savings: Minimizing machine failures reduces repair costs and the need for expensive replacements.
- Employee engagement: Operators gain new skills and take pride in maintaining their equipment, which boosts morale and accountability.
- Streamlined maintenance operations: Maintenance teams can focus on more complex repairs and improvements, optimizing resource allocation.
Implement autonomous maintenance in these 7 steps
To successfully roll out autonomous maintenance, you can follow these seven structured steps designed to build operator competence, standardize practices, and foster continuous improvement.
Step 1: Initial cleaning of machines and workstations
The first step involves a thorough cleaning of machines and their surrounding work areas. This may seem simple, but it’s critical because dirt, dust, and grime can mask early signs of wear or damage. Cleaning also helps operators to get intimately familiar with their equipment and creates a baseline condition. Use checklists to ensure no area is overlooked. Involve maintenance experts to guide operators on what to look for and how to clean sensitive components safely.
Step 2: Eliminating sources of dirt and problems
After initial cleaning, it is essential to identify and remove the root causes of contamination and recurring problems. If dirt or issues keep reappearing, your cleaning efforts won’t be sustainable. Pinpointing the sources – like leaking seals, faulty filters, or poor workplace layout – helps prevent contamination from recurring. Conduct inspections alongside operators and maintenance staff to track contamination sources. Implement fixes such as replacing worn seals, improving ventilation, or reorganizing tools and materials. Document these actions so the improvements become part of your maintenance routine.
Step 3: Establishing standards
Consistency is key. This step focuses on creating standard operating procedures (SOPs) for routine maintenance tasks and machine checks. They serve as clear guides that make autonomous maintenance manageable and effective. Therefore, develop detailed checklists, schedules, and visual aids outlining daily, weekly, and monthly maintenance tasks. Collaborate with operators and maintenance experts to make sure standards are realistic and comprehensive. Regularly review and update standards as equipment or conditions change.
Step 4: Enhancing operators’ technical skills
Autonomous maintenance requires operators to understand their machines beyond basic operation. To achieve this goal, you make use of proper training. This builds confidence and competence, enabling operators to detect abnormal conditions and perform maintenance tasks safely and correctly. Also provide hands-on training sessions, giving more information about machine components, lubrication techniques, inspection methods, and troubleshooting basics.
Step 5: Autonomous inspections: Improving and revising checklists
Once standards and skills are in place, operators should regularly inspect their equipment using checklists designed to catch early warning signs. Frequent inspections prevent minor issues from developing into serious problems and allow timely intervention – and that is exactly what you want. Equip operators with comprehensive checklists that evolve based on experience and feedback. Use simple scoring or traffic-light systems to highlight condition status. Encourage operators to suggest checklist improvements and share best practices during team meetings.
Step 6: Standardizing and visualizing
Visual management tools help make maintenance status visible and actionable for everyone. This way, they make it easier to track maintenance activities and identify deviations from standards. Implement color-coded labels, shadow boards for tools, and clear signage for lubrication points or inspection intervals if you want to create an excellent overview.
Step 7: Continuous improvement
Autonomous maintenance is not a one-time project but a continuous cycle of refinement. This ongoing improvement ensures your maintenance program adapts to changing conditions, technology, and team capabilities, maintaining high equipment reliability. Encourage operator feedback and recognize contributions that lead to improvements. Also, establish regular review sessions to analyse inspection data, discuss problems, and implement corrective actions.
What is the difference between autonomous and preventive maintenance?
While both autonomous and preventive maintenance aim to keep equipment in top condition, they differ fundamentally in approach and responsibility. Autonomous maintenance focuses on operators performing routine maintenance tasks daily, such as cleaning and inspections, to prevent deterioration. Preventive maintenance is typically scheduled and carried out by maintenance specialists, involving more technical tasks like part replacements, adjustments, and system checks.
In conclusion, autonomous maintenance is about empowering operators to manage the basics, while preventive maintenance involves planned, expert interventions to prevent major failures. Would you like to read more about preventive maintenance? Check out our blog about preventive maintenance!
How does the EZ-GO connected worker platform help with autonomous maintenance?
Implementing autonomous maintenance can be complex without the right tools. The EZ-GO connected worker platform simplifies this process by providing digital work instructions, checklists, and real-time reporting tools directly on operators’ mobile devices. By digitizing autonomous maintenance, EZ-GO boosts operator engagement, enhances data accuracy, and accelerates problem resolution, making your autonomous maintenance program more effective and scalable. With the use of clear visual instructions – including multiple photo and video guides – maintenance tasks become significantly easier to understand. This allows operators to perform tasks independently, without requiring prior training or extensive technical knowledge.
Need more info about autonomous maintenance? Contact us!
Whether you want to learn more about autonomous maintenance or explore how the EZ-GO connected worker platform can support your journey, we are here to help. Make sure to contact us for personalized advice, demos, and support tailored to your company’s needs.