There are seven steps for successfully implementing an autonomous maintenance program:
Step 1: Boost machine operator knowledge.
It’s vital that machine operators know about the machines they’re working on. Creating an autonomous maintenance checklist is a great way to train them on how to detect equipment malfunctions. This can include work procedures on how to keep equipment operating in like new condition.
Operators must know the technical details of a machine’s components and potential equipment-related issues. This knowledge can help them identify any machine abnormalities and fix issues.
Step 2: Conduct initial cleaning and repairs.
It’s important to perform initial maintenance to bring equipment up to like-new condition. This step includes looking for leaks, cracks, loose bolts, contamination, and unusual sounds or smells.
Step 3: Remove causes of contamination.
Once the initial cleaning is completed and equipment has been restored to operate like new, it’s vital to implement practices that will keep it that way. Contamination needs to be prevented in order to ensure equipment doesn’t deteriorate. This begins with promoting good cleaning habits and includes using sealing methods and machine covers to protect equipment.
Keep in mind that cleaning a machine while it’s still running is very dangerous. Make sure to provide your team with step-by-step instructions on how to properly shut off machines and conduct maintenance.
Step 4: Create standards for cleaning, lubrication, and inspection.
Documenting a digital record of standards on cleaning, inspecting, and lubricating helps operators know what to focus on. Digital checklists on work procedures can be a beneficial way to drive consistency and compliance across steps.
Step 5: Conduct inspection and monitoring.
By this step, machine operators now have the tools and training to conduct regular inspections and monitor equipment. They are in charge of identifying any equipment-related issues and preventing them from becoming major problems.
Step 6: Implement visual maintenance.
Visual maintenance means monitoring what is going on with every piece of machinery. Consider adding photos, symbols, and color-coding to your checklist to help operators identify what needs to be fixed and how to do it.
Step 7: Aim for continuous improvement.
Striving for better ways to perform tasks is vital in autonomous maintenance. This can be achieved by reviewing current practices and procedures and making adjustments.