How to Implement an Autonomous Maintenance Program

Autonomous maintenance (AM) can significantly streamline your preventive maintenance tasks. That’s because you can spend less time allocating maintenance resources to all the equipment in your facility. It’s also a way to lessen the amount of maintenance needed when specialized maintenance staff perform routine tasks.

Autonomous maintenance allows operators to identify and resolve minor issues before they escalate into major problems. As a result, specialized maintenance staff have more time to focus on more technical and complex problems.

However, given the nature of AM, improper implementation is a big risk. If machine operators aren’t trained correctly, the system can inadvertently do more harm than good. For this reason, you must thoroughly research AM and how to implement autonomous maintenance before adding it to your maintenance strategy.

What is Autonomous Maintenance?

Autonomous maintenance involves assigning machine operators responsibility for maintenance tasks instead of relying solely on maintenance personnel. It’s a key pillar of Total Productive Maintenance (TPM). However, you will still need to call a maintenance technician for more complex maintenance tasks. The focus is on training operators to perform basic upkeep tasks to simplify the work that maintenance technicians will need to do.

Some of the key benefits of autonomous maintenance include reduced maintenance costs, less time spent on maintenance tasks, slower equipment deterioration, and a more engaged and skilled workforce. Additionally, this approach promotes a safer working environment by encouraging operators to take proactive measures in equipment care.

However, leaving preventative maintenance tasks to people who aren’t trained as maintenance technicians carries risks. That’s why properly implementing autonomous maintenance is so important.

8 Steps of Autonomous Maintenance Implementation for Success

The steps of autonomous maintenance focus on giving operators the responsibility and skills needed to maintain their own equipment. This approach increases machinery lifespan and efficiency by involving those who use the equipment daily.

Here are the specific steps to effectively implement autonomous maintenance in your facility:.

1. Clearly Define Roles and Responsibilities

Generally, assigning AM only to operators for the equipment they work with is best. That’s because they already have some specialized skills that help them understand how that specific piece of equipment functions. Starting with general equipment-related skills is their first step to understanding equipment maintenance.

Additionally, like any maintenance program, it’s important to proactively establish an autonomous inspection schedule. Having this schedule tells your operators exactly when they need to service their equipment as instructed and trained.

2. Train Operators on Specific AM Tasks

Maintenance staff must train operators on the specific AM tasks they will own, such as initial cleaning, inspection, lubrication, and simple repairs. This ensures that machine operators will perform maintenance tasks correctly, preventing unintended equipment damage and keeping operators safe.

3. Start Small With a Pilot Machine

Begin AM on a pilot machine or line and prove the concept before spreading it to other assets. Starting small allows maintenance processes to be refined before they are rolled out across your facility. It’s also a good way to proactively test for quality issues and determine an effective autonomous maintenance schedule.

4. Dedicate Time for Operators to Perform AM Work

Operators will need additional time to complete maintenance tasks. Make sure you give them enough time to perform maintenance tasks. This time is not part of their normal production responsibilities; it must be an add-on alongside their operational tasks.

5. Standardize Visual Maintenance Management

Use visual aids like color coding, labeling, SOPs, one-point lessons, and other visual factory techniques to make AM tasks intuitive. These cues will help ensure proper management of regular maintenance tasks. It will also empower operators to become more independent.

6. Leverage Operator Insights

Operators are closest to the equipment and can often detect issues before they trip alarms. Have a simple way for them to submit work requests to your dedicated maintenance technicians when needed. Discourage them from trying to fix issues if it isn’t among the tasks they were trained to do.

7. Share Equipment Health and Performance Data

Give operators access to reliability metrics for their equipment so they understand how their AM efforts are improving equipment performance. Monitoring maintenance data can also show them where improvements can be made and where routine maintenance is still required.

8. Continuously Improve AM Through Kaizen Events

A kaizen event is a short-term brainstorming session that targets a specific challenge and enhances an existing process. The term comes from the Japanese words that mean “change for the better.” Conduct kaizen events with your operators and maintenance engineers to facilitate continuous improvement and come up with innovative ways to prevent equipment failures.

The Role of Technology in Autonomous Maintenance Tasks

Technology can play an important role in your total productive maintenance strategies. Advanced tools and systems provide essential support by automating data collection, enabling real-time monitoring, and facilitating more accurate maintenance decisions.

Computerized Maintenance Management Systems (CMMS)

Computerized maintenance management systems (CMMS) make it much easier to plan, track, and document autonomous maintenance tasks. These systems also provide a centralized platform for monitoring data collected and managing records on maintenance tasks fulfilled.

Sensors and Industrial Internet of Things (IIoT)

Sensors and the industrial Internet of Things (IIoT) allow for real-time equipment monitoring, sharpening the accuracy of condition-based maintenance strategies. They can also detect early signs of equipment failure and independently identify quality issues before inspection tasks are conducted.

Machine Learning and AI

Machine learning and AI support predictive maintenance and streamline fault detection. They also help in analyzing large volumes of data to optimize maintenance schedules. Plus, these technologies adapt and improve their predictions over time, which can help enhance maintenance outcomes as your facility’s needs change.

Mobile Devices

Mobile devices make it easier to deliver AM instructions and checklists to operators. They also facilitate real-time communication between team members during maintenance activities, which can increase operator knowledge. Operators also use these devices to instantly report issues and accelerate maintenance responses.

Data Analytics

Data analytics can be used to measure AM effectiveness and identify opportunities for continuous improvement. By tracking trends and making data-driven decisions, teams can enhance how they perform basic maintenance tasks. Additionally, this analysis offers insights into prevalent maintenance challenges, which can inform future training and development initiatives.

Why Partnerships Matter for Autonomous Maintenance Success

By fostering an environment of teamwork, managers can maximize the benefits of autonomous maintenance and their other preventive maintenance strategies. With operators and maintenance teams working as partners, autonomous maintenance can drive overall equipment effectiveness, prevent equipment deterioration, enhance reliability, and lower labor costs.

However, you must not use AM as a replacement for conducting routine inspections. Even with solid operator care, periodic maintenance is still critical. Strive for the right balance and hand-offs between the two. Regular communication and knowledge sharing between the two groups is key to sustaining autonomous maintenance alongside your preventive maintenance program.

Joint problem-solving helps eliminate sources of contamination and wear. Reducing these sources will greatly enhance asset lifespans and ensure consistent, proper operation. Celebrating instances where collaboration prevented complex equipment-related issues encourages the practice to continue.

All of the above is only possible with buy-in from leadership. Leadership is critical, as only they can give operators the time they need to maintain equipment and establish continuous improvement techniques.

Drive Reliability in Your Autonomous Maintenance Program With ServiceChannel

After you implement autonomous maintenance, you need an efficient way to manage it. As discussed, the right technology can help your team streamline their equipment and maintenance tasks. 

ServiceChannel provides a user-friendly preventive maintenance management solution. Our platform can help you track inspection reports and resource allocation, as well as assist with inspection and monitoring data—and much more.