Operator Asset Care - The Workforce-Centric Approach

5 Mar

The Workforce-Centric Approach to your Maintenance Operations

In manufacturing, maintaining equipment reliability has never been more critical. With increasing downtime, skills shortages, and ageing machinery, traditional maintenance approaches are struggling to keep up.

Operator Asset Care (OAC) offers a structured solution by reshaping the role of operators within maintenance strategies, enabling a more proactive and collaborative workforce.

The Shift in Workforce Dynamics

OAC is not simply about keeping machines clean and running; it is about integrating operators into the maintenance process. By equipping them with the right training and responsibilities, they can detect early signs of deterioration and contribute to preventive maintenance efforts. Rather than waiting for engineers to step in, operators take on routine tasks such as cleaning, lubrication, and minor adjustments.

This approach ensures that maintenance teams can focus on more complex, high-value tasks, optimising the workforce by improving collaboration between operators and engineers. With structured communication and defined roles, OAC fosters a proactive maintenance culture where potential failures are addressed before they become critical issues.

Key Stakeholders in Manufacturing Operations

Closing skills gaps with an OAC strategy requires collaboration between multiple teams within a manufacturing organisation. These teams can be categorised into three key groups:

Engineering & Maintenance Management
Oversee operations, ensure equipment reliability, and implement maintenance strategies while supporting overall business objectives.
Process Experts
The hands-on professionals who keep production running. With deep process knowledge, they are the first to detect issues and play a crucial role in maintaining efficiency.
Problem Solvers
The trouble-shooters who step in when things go wrong, including maintenance engineers and technical specialists who diagnose and resolve issues to ensure long-term reliability.

By ensuring strong collaboration among these three groups, organisations can create a proactive maintenance culture, where operators take greater responsibility for equipment performance while maintenance teams focus on complex, high-value tasks.

Roles & Responsibilities within an OAC Programme

Operators

Operators are trained to operate equipment correctly, perform routine inspections, and follow standard operating procedures (SOPs) to ensure equipment is used within its designed parameters. They are the first line of defence in detecting equipment issues, recognising early signs of problems, and taking preventive measures before issues escalate. Additionally, operators are responsible for tasks such as cleaning, lubrication, and minor adjustments, and they document their maintenance activities and any issues they encounter.

Maintenance Teams

Collaboration between Operators and Maintenance Teams is essential for the successful implementation of OAC. Clear communication channels and defined roles and responsibilities ensure that both groups work together towards the common goal of maximising asset performance. Regular meetings and feedback sessions help address any challenges and continuously improve maintenance practices.

Maintenance Responsibilities

Preventative and predictive maintenance
Condition monitoring
Equipment testing
Overhauls and major servicing
General repairs/breakdowns
Feedback and analysis of work data
Review and selection of maintenance approaches
Maintenance technology improvement
Work practices improvement
Reliability & maintainability improvement
OEE improvement