How to Empower Operators to Do Autonomous Maintenance

Autonomous maintenance is a core pillar of Total Productive Maintenance (TPM) that empowers machine operators to handle basic upkeep tasks - such as cleaning, inspection, and lubrication—without depending entirely on maintenance technicians.

By enabling frontline operators to detect and correct issues early, autonomous maintenance reduces unplanned downtime, increases equipment reliability, and frees maintenance teams to focus on more complex, value-added work.

Common tasks include checking fluid levels, tightening bolts, cleaning equipment, inspecting belts and filters, and reporting abnormalities using visual management tools like checklists or dashboards.

Visual management tools—such as inspection boards, digital work instructions, and skill matrices—help operators know exactly what to do, when to do it, and how to perform maintenance tasks safely and consistently.

Manufacturers adopting autonomous maintenance have reported up to 50% fewer unplanned stoppages, significant improvements in overall equipment effectiveness (OEE), and stronger engagement among frontline workers.