The Shift to Autonomous Maintenance in Manufacturing

Fauzi Baharin is recognized for his attention to detail and precision in the handling and manipulation of manufacturing processes. With a proven track record of expert communication, he has successfully collaborated with various teams, including Technical Service & Development, Commercial, Design, Engineering, Supply Chain, Quality Assurance, and Operations. He has established standards that have reduced costs, enhanced efficiency, improved production methods and simplified equipment and part needs. In his role, he provides strong support in cultivating an environment that encourages problem-solving and critical thinking, identifying solutions to complex problems.

Through this article, Fauzi shares his insights on the shift from traditional maintenance practices to the implementation of Autonomous Maintenance (AM) within manufacturing environments.

Isn’t it normal for production operators or front-line workers to solely depend on maintenance or engineering technicians to resolve and rectify any equipment breakdown or minor repairs? That is not happening now as most manufacturing companies are moving towards Autonomous Maintenance (AM). 

Autonomous Maintenance (AM) is a concept within Total Productive Maintenance (TPM) which is a methodology focusing on maximizing the productivity of manufacturing equipment. Autonomous maintenance refers to the practice of empowering operators or front-line workers to take ownership of the maintenance and minor repairs of the equipment. 

As an Autonomous maintenance pillar lead for the site, I’ve emphasized six key objectives to my production team: - 

1) Equipment ownership and accountability: Operators are responsible for the day-to-day care and maintenance of their equipment. This fosters a culture of pride in their work and a commitment to keeping equipment in optimal condition. 

2) Reduced downtime: Operators conduct routine checks, inspections and minor repairs to prevent any breakdowns and equipment failures. 

3) Skill development: Operators develop technical skills related to equipment maintenance, troubleshooting and problem-solving. Learning autonomous maintenance enhances operators' technical skills and understanding of the equipment they work with daily. 

4) Improved efficiency: Autonomous maintenance helps streamline maintenance activities, as operators can perform tasks such as cleaning, lubricating, and basic inspections without waiting for specialized maintenance personnel. This improves overall equipment efficiency and productivity. 

5) Cost savings: By reducing downtime and minimizing the need for major repairs, autonomous maintenance can result in significant cost savings for the organization when the performance of the equipment has been optimized. 

6) Cultural shift: Autonomous maintenance fosters a culture of continuous improvement and teamwork, as operators work closely with maintenance or engineering personnel and management to optimize equipment performance. 

Autonomous maintenance not only benefits the organization by improving operational efficiency and reducing costs but also empowers operators, fosters a culture of teamwork and continuous improvement, and enhances overall equipment reliability.

To a large extent, autonomous maintenance is a cornerstone of TPM, helping organizations achieve higher levels of equipment reliability, efficiency, and overall operational excellence. 

Autonomous maintenance not only benefits the organization by improving operational efficiency and reducing costs but also empowers operators, fosters a culture of teamwork and continuous improvement, and enhances overall equipment reliability. 

It’s essential to address the operator’s concern and understand the underlying reasons for their resistance to supporting and learning autonomous maintenance. Here are common reasons why operators might be hesitant to embrace autonomous maintenance and strategies to address these challenges: - 

1) Fear of changes: Introducing autonomous maintenance represents a significant change in roles and responsibilities for operators. Communicating the benefits of autonomous maintenance, such as reduced downtime, increased equipment reliability and skill development opportunities, can help alleviate fears and resistance to change.

2) Lack of training: Operators may feel unprepared or lack the necessary skills to perform maintenance tasks independently. Providing comprehensive training programs that cover equipment operation, maintenance procedures, and troubleshooting techniques can help build their confidence and competence. 

3) Lack of time or resources: Operators may feel overwhelmed by their existing workload and perceive autonomous maintenance as an additional burden. Prioritizing tasks, streamlining processes, and providing adequate resources and support can help make autonomous maintenance more manageable and less disruptive to daily operations. 

4) Resistance to taking on more responsibilities: Some operators may resist autonomous maintenance because they prefer to focus solely on production tasks rather than maintenance responsibilities. Highlighting the long-term benefits of increased ownership, skill development, and job satisfaction can help motivate operators to embrace their expanded role in equipment maintenance. 

By addressing these concerns and actively involving operators in the process, organizations can overcome resistance and create a culture where autonomous maintenance is embraced as a valuable strategy for improving operational efficiency and equipment reliability.