Article 4- Operator-led Maintenance Enhances Plant Safety

Autonomous maintenance, also known as operator-led maintenance, involves empowering frontline

workers to take responsibility for the maintenance of equipment and facilities. When implemented
effectively, autonomous maintenance can contribute to a safer working environment in
manufacturing facilities. Some positive changes that can be experienced are:

1. Early detection of equipment issues: Autonomous maintenance encourages frontline

workers to conduct regular inspections and checks on equipment and facilities as part of
their routine tasks. This enables them to detect potential issues or abnormalities early, such
as loose bolts, leaks, or worn-out parts, which could pose safety risks. Early detection allows
for timely intervention to address the issues before they lead to accidents or disruptions.

2. Timely maintenance and repairs: Autonomous maintenance empowers frontline workers to

perform minor maintenance tasks, such as tightening bolts, lubrication, and simple repairs.
This helps in addressing maintenance needs promptly, preventing equipment from
deteriorating further and reducing the risk of failures or breakdowns that could cause safety
hazards.

3. Improved equipment reliability: Proper maintenance through autonomous maintenance can

contribute to improved equipment reliability. Regular inspections, cleaning, and
maintenance activities performed by frontline workers improves Mean Time to Repair
(MTTR) for a specific equipment and or a line. can prevent equipment from malfunctioning
or failing during operation, reducing the risk of accidents or disruptions.

4. Enhanced equipment safety measures: Autonomous maintenance encourages frontline

workers to actively engage in safety measures, such as cleaning, inspecting, and replacing
safety guards, shields, or sensing parts sensors. This ensures that safety measures are well-
maintained and functioning effectively, reducing the risk of accidents or injuries.

5. Training and awareness: Autonomous maintenance typically involves training frontline

workers on equipment operation, maintenance procedures, and safety protocols. This helps
to raise know-how of how to maintain a specific equipment even in the absence of an
experienced personnel on-site, thus awareness of about potential hazards and ensures that
workers are trained to operate and maintain equipment safely, contributing to a safer
working environment.

6. Continuous improvement: Autonomous maintenance encourages frontline workers to

provide feedback on equipment performance, maintenance needs, and safety concerns. This
feedback can be used to drive continuous improvement in maintenance best practices,
equipment design, and update safety protocols, leading to an efficient and safer working
environment over time.

Enabling autonomous maintenance is a combination of effective training, communication, process

streamlining and support from management. Autonomous maintenance can help create a safe and
effective and safety work culture where all employees are actively engaged in ensuring the safety of
the work environment.

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