Operators are the heart and soul of any manufacturing facility, playing a crucial role in ensuring smooth operations and preventing mechanical issues. Their first-hand knowledge of common problems and inefficiencies can be invaluable in maintaining optimal mechanical performance. That's why implementing a comprehensive operator asset care system is essential for every factory. Operator asset care involves involving operators in the maintenance and optimization of their machines, enabling early detection of equipment issues and allowing maintenance teams to focus on more intricate problems. In this Blog, we will delve into the fundamentals of operator asset care, outline its benefits and challenges, and provide best practices for successfully implementing an OAC program within your organization.

What is Operator Asset Care?

Operator asset care, rooted in the principles of autonomous maintenance within Total Productive Maintenance (TPM), emphasizes the importance of involving manufacturing operators in machine maintenance. By empowering operators to perform basic maintenance tasks and providing them with the necessary training, organizations aim to minimize asset failures proactively. This strategic approach equips operators to promptly identify and resolve mechanical issues, fostering a culture of preventive maintenance through the implementation of straightforward checklists that operators can autonomously execute. With OAC, companies enhance operational efficiency, promote equipment longevity, and ultimately optimize production processes. An OAC checklist could include some or all of the following tasks:

Machine cleaning

Ensuring assets remain clean by eliminating dust, debris, and any other materials that could disrupt their functionality.

Lubrication

Ensuring that moving components are properly lubricated to prevent deterioration.

Wear and tear inspection

Conducting thorough examinations of machinery and equipment to detect indicators of excessive wear and tear, such as frayed cables, cracks, and worn-out belts.

Safety inspections

Confirming the presence of all safety guards and the functionality of emergency stops and safety devices.

Leakage inspections

Examining hydraulic systems, air compressors, and other areas for any leaks in fluids or gases.

Electrical system reviews

Verifying the condition of electrical connections for any indications of overheating, corrosion, or loose connections.

Calibration of control systems

Validation of the proper calibration and functionality of all control systems, such as temperature, pressure, and flow controls.

Air filter maintenance

Examination and replacement of air filters when necessary to maintain optimal airflow and prevent any potential contamination.

Verification of cooling system efficiency

Ensuring the effective operation of cooling systems by monitoring coolant levels and inspecting radiators and fans to guarantee optimal performance.

By actively involving operators in the asset maintenance process, they have the opportunity to identify and potentially address emerging issues before they escalate into expensive breakdowns.

Distinctions between OAC, TPM, and Autonomous Maintenance

While OAC is commonly integrated into a plant's TPM strategy, it can also be utilized independently. Furthermore, the terms operator asset care and autonomous maintenance are often used synonymously, with OAC stemming from the latter. To avoid confusion among these maintenance concepts, let’s break down the differences:

Total Productive Maintenance (TPM)

A comprehensive asset maintenance approach that involves all areas of the factory. By combining various maintenance strategies and optimization efforts, TPM strives to enhance asset efficiency by minimizing downtime, defects, and safety incidents.

Autonomous Maintenance

Autonomous maintenance is a key aspect of Total Productive Maintenance (TPM) whereby operators are empowered to conduct basic troubleshooting and maintenance tasks that are typically carried out by technicians. This approach is more comprehensive than Operator Asset Care (OAC), as it involves transferring a greater amount of maintenance-related responsibilities to operators compared to a standard OAC program.

Operator Asset Care

In contrast to autonomous maintenance, OAC emphasizes on performing daily maintenance tasks regularly to maintain smooth equipment operation. These tasks under operator asset care do not demand comprehensive training or specialized maintenance expertise.

Best Practices for Implementing Operator Asset Care

To successfully incorporate operator asset care (OAC) into a factory setting, manufacturers must engage in meticulous planning and seamless integration of processes that enable operators to proficiently uphold their equipment. Below are recommended steps for manufacturers to follow in order to guarantee the prosperity of their OAC initiatives:

Create an Extensive Training Program

Operators should receive both basic and advanced training on the machinery they use. One option is to utilize Nirmalya Enterprise Platform Suite for delivering digital, on-demand training. This ensures that all operators have access to uniform and current training materials and tutorials.

Create Concise Maintenance Procedures

Develop comprehensive checklists and maintenance schedules for individual machines, sharing these procedures electronically. Utilize the capabilities of the Nirmalya Enterprise Platform Suite to issue alerts to operators, monitor task progress, and adjust protocols in real-time according to machine data and operator input.

Establish Regular Inspections and Generate Reports

Ensure routine inspections are conducted and promote operators to notify any anomalies. Utilize a digital communication platform such as Nirmalya Enterprise Platform Suite that enables operators to send instant reports and images directly from the manufacturing floor using mobile devices. Timely reporting can expedite problem resolution, minimizing downtime and maintenance expenses.

Encourage a Culture Focused on Ongoing Enhancement

Encourage operators to share ideas for enhancing maintenance practices and equipment efficiency. Enable idea exchange and teamwork throughout the factory, giving operators the opportunity to participate in conversations, exchange best practices, and offer feedback. This initiative not only enhances maintenance practices, but also increases operator involvement and job satisfaction.

Track and Assess Data on Equipment Performance

Employ sensors and IoT devices for gathering data on the usage and performance of equipment. Conduct analysis on this data to uncover valuable information regarding maintenance requirements and operational effectiveness. The utilization of a data-driven method for performance evaluation facilitates predictive maintenance, allowing operators to proactively deal with potential issues before they result in equipment breakdowns.

Regularly Review and Adjust OAC Program as Needed

Continuously assess the operator asset care program's effectiveness and make necessary adjustments utilizing feedback and performance data. This ongoing process guarantees that the maintenance program evolves to address evolving factory and equipment requirements while upholding superior standards of operational efficiency and safety.

Manufacturers can enhance their operator asset care program by integrating the steps with Nirmalya Enterprise Platform Suite. This integration can lead to improved communication, increased efficiency, and the fostering of a proactive maintenance culture within the factory.

Challenges Associated with Operator Asset Care

Below are several typical challenges that even the most sophisticated industrial firms encounter when implementing and enhancing their operator asset care programs.

Insufficient Backing from Senior Management

Strong support from senior management is essential for the success of operator asset care programs. Without this support, there is a risk of inadequate funding, limited resources, and lack of prioritization, which can hinder the effective implementation and sustainability of the program. Furthermore, management's dedication is crucial for facilitating cultural shifts and emphasizing the significance of maintenance throughout the organization.

Insufficient Operator Training

Effective training of operators is essential for the success of an asset care program. Issues may arise when training is insufficient or not tailored to the equipment needs or operator skills. This can result in incorrect maintenance procedures, potentially leading to equipment damage or reduced efficiency.

Inadequate Communication among Maintenance and Operator Teams

Proper communication between maintenance technicians and operators is essential for coordinating maintenance tasks and exchanging critical information regarding equipment status and performance. Inadequate communication may result in duplicated efforts, overlooked maintenance opportunities, or lingering equipment problems, all of which can have a detrimental impact on plant productivity.

Ambiguity in Delineating Responsibilities

Establishing clear boundaries and responsibilities between operators and maintenance technicians can prove to be a difficult task. When roles and responsibilities are not clearly defined, it may result in uncertainty regarding accountability for maintenance tasks, potentially leading to overlooked duties or exceeded boundaries. This can have a detrimental impact on both morale and operational effectiveness.

Cultural Resistance to Change

Cultural resistance from operators and maintenance teams can hinder the implementation of operator asset care. Operators may resist taking on additional duties, while maintenance personnel could see it as a threat to their roles. Overcoming this resistance requires demonstrating the benefits and ongoing engagement from all levels of the organization. Adequate training for operators on the tools and methods needed for maintenance tasks is essential for successful technology adoption.

Resource Allocation

Manufacturers often struggle with allocating resources between production tasks and maintenance duties. The tendency to prioritize production over maintenance can result in equipment failure. To address this issue, manufacturers should view maintenance activities as essential to the production process and utilize digital solutions like connected workforce software to coordinate schedules and balance short-term production goals with long-term equipment health.

Streamline OAC with Nirmalya Enterprise Platform

When setting up or enhancing an OAC program in your factory, it is essential to make sure that your operators always have access to the correct instructions. Nirmalya Enterprise Platform is created to digitalize and decentralize crucial, role-specific information throughout the shop floor, enabling operators and maintenance teams to swiftly troubleshoot issues.

Production Management feature of Nirmalya Enterprise Platform Suite provides operators with immediate insights into machine performance and promptly notifies them of any mechanical issues. Using an intuitive operator console, employees can access digital instructions for simple troubleshooting steps and efficiently create service requests for more complex problems that require a maintenance technician's assistance.

Maintenance technicians have the ability to access a role-specific platform through Enterprise Asset Management. This allows them to effectively diagnose mechanical issues, procure necessary parts, execute repairs, and record the entire process. Equipped with the necessary information, maintenance teams can efficiently and accurately complete repairs, reducing both downtime and maintenance expenses.

Contact us today to learn how Nirmalya Enterprise Platform Suite can optimize operator asset care tasks in your plant with its unique capabilities!