Autonomous Maintenance (AM)

All industrial companies are well aware that effective management and maintenance of machinery is key to ensuring continuous production, minimizing downtime and maximizing operational efficiency. Therefore, the issue of Autonomous Maintenance (AM for short) should be familiar to anyone for whom the technical condition of machinery is important.

The concept of Autonomous Maintenance is derived from the philosophy of Total Productive Maintenance, which was developed in Japan in the 1970s. Both TPM and AM aim to increase the efficiency of machines.

Autonomous Maintenance is an approach in maintenance whereby machine operators are responsible for basic maintenance tasks. The goal of AM is to increase employee involvement in machine maintenance and increase responsibility for machine condition.

Benefits of Autonomous Maintenance

• Improving machine reliability. This is one of the primary goals of using AM. Operators who are involved in the monitoring and maintenance of machinery and equipment are able to detect and respond to errors more quickly. Thanks to this preventive approach, minor problems are resolved quickly, resulting in far fewer major failures.
• Reduction in downtime. This benefit is the result of the activities described above. Regular maintenance activities performed by operators contribute to a reduction in breakdowns and downtime, which in turn leads to increased machine availability and production continuity.
• Reduction of maintenance costs. Taking care of the technical condition of machines directly translates into extending their service life and reducing expenses for repairs and replacement of spare parts.
• Increasing operator engagement. The AM concept strongly promotes a culture of shared responsibility and involvement among employees. As a result, operators who are trained and empowered to carry out maintenance activities feel more responsible for their workstations and treat their equipment as “their own.”

Implementation of AM – Autonomous Maintenance

The process of implementing AM requires decent planning. At the initial stage, you need to identify the machines and processes that will be covered by AM. In addition, the scope and schedule of activities need to be defined. Representatives of the maintenance department, as well as machine operators, should be involved in this process.

The next stage is the pilot. Then tests are carried out and the effectiveness of the developed AM is evaluated in a so-called pilot area, for example, on one production line or selected workstations. Pilot activities allow the identification of possible problems and their repair before implementing AM “on a full scale.”

After the pilot stage, we move to full AM implementation. At this stage, we train machine operators. The training includes not only discussion of technical issues (such as cleaning, oiling, lubricating, changing filters, etc.), but also awareness issues – employees need to know why they should engage in maintenance activities. Failure to explain to operators why “we’re doing it” often results in meeting resistance to the changes that the implementation of Autonomous Maintenance brings. It is also worth mentioning that operators need to feel the support of the maintenance staff, the implementation must not end with the delegation of responsibilities. Maintaining commitment and ensuring that the maintenance activities carried out are effective requires the ongoing support of the UR department.

It is also important to remember that Autonomous Maintenance is a dynamic process that requires continuous improvement. Regular reviews, analysis of results, and implementation of improvements are key to maintaining high AM performance.

NOTE: Before implementing AM, it is extremely important to implement 5S in the organization and standardize activities, especially maintenance activities. It will also be a great help to implement visual management, which makes it easier for employees to carry out visual inspections, for example.

AM implementation process

Technologies supporting Autonomous Maintenance

In the third decade of the twentieth century, it is impossible not to mention the impact of technology on AM, which, skillfully used, can be quite a convenience for operators, maintenance workers, production and management alike.

Artificial Intelligence (AI) and Machine Learning

Artificial Intelligence and Machine Learning support AM through data analysis and failure prediction. AI algorithms can identify patterns and trends that indicate potential problems, allowing for proactive action and avoiding costly machine failures.

Internet of Things (IoT)

The Internet of Things is playing an increasingly important role in AM, enabling real-time remote monitoring of machine conditions. IoT sensors can provide data on machine operating parameters, allowing early detection of problems and planning of maintenance activities.

Computerised Maintenance Management Systems (CMMS)

CMMS systems are key tools supporting Autonomous Maintenance. CMMS enable management of maintenance schedules, machine condition monitoring, reporting and data analysis.

Augmented Reality (AR)

Augmented Reality (AR) technology can be used to train operators and support them in performing maintenance tasks and complying with health and safety regulations in the process. AR makes it possible to display instructions and information directly on machines, which facilitates maintenance and repairs. It is worth mentioning that such a way of training operators allows simulating situations in which, for example, an operator does not follow health and safety rules. Displaying a potential accident at work as a result of operators’ failure to observe basic safety rules actually makes them more cautious and aware of risks.

Technologies supporting Autonomous Maintenance

In summary, Autonomous Maintenance is a modern approach to maintenance that involves machine operators in basic maintenance activities. With regular inspection and maintenance performed by operators, it is possible to increase machine reliability, reduce downtime, increase employee engagement and optimize costs. Implementing AM requires careful planning, training of employees, standardization of activities and introduction of the 5 steps of the 5S method.