The Seven Stages of OAC
The Seven Stages of OAC: Building a Collaborative Maintenance Culture
Operator Asset Care (OAC) is a structured approach that empowers frontline employees to take ownership of equipment maintenance. The programme progresses through seven key stages, each building upon the last to create a culture of continuous improvement and self-management.
The Seven Stages of OAC
1. Basic Cleaning by Employees
Equipment failures cause unexpected downtime, significantly impacting production schedules and profitability. Reactive maintenance means businesses are often firefighting issues rather than preventing them. The foundation of OAC starts with engaging employees in routine cleaning of their equipment. This serves multiple purposes:
Helps operators become familiar with the machinery, making it easier to detect abnormalities.
Prevents dirt, dust, and debris buildup, which can lead to performance issues.
Reduces wear and tear by ensuring moving parts remain clean and unobstructed.
Encourages a sense of ownership and pride in maintaining a well-kept workspace.
2. Eliminate Causes of Pollution & Contamination
Once basic cleaning is established, the next step is identifying and eliminating sources of contamination that degrade equipment performance. This includes:
Addressing oil leaks, dust accumulation, and residue buildup that can lead to early failures.
Implementing proper waste disposal and material handling procedures.
Ensuring correct lubrication and sealing to prevent contamination.
Reducing environmental factors (e.g., excessive heat, moisture, or vibration) that contribute to deterioration.
3. Standard for Basic Maintenance
Operators are then trained to perform essential maintenance tasks that prevent minor issues from escalating into major failures. This stage involves:
Establishing clear and repeatable maintenance procedures for operators.
Training employees in basic inspections, lubrication, and fastener tightening.
Documenting and standardising daily, weekly, and monthly maintenance tasks.
Ensuring proper use of tools and safety procedures when performing basic maintenance.
4. Developing Employees’ Skills
At this stage, employees deepen their technical understanding of equipment and develop problem-solving skills. Key focus areas include:
Training on machine functions, key failure modes, and early detection of issues.
Encouraging a culture of continuous learning and skill development.
Introducing troubleshooting techniques to improve diagnostic capabilities.
Empowering teams to work alongside maintenance engineers to enhance their technical knowledge.
5. Standards for Independent Inspection
With improved knowledge and skills, employees now take responsibility for inspecting their equipment independently. This ensures early fault detection before problems escalate. This stage involves:
Defining inspection standards for different equipment types.
Training employees to recognise warning signs such as leaks, unusual noises, or increased vibration.
Introducing structured checklists to standardise inspection routines.
Developing easy-to-follow repair and maintenance guides.
Using videos to demonstrate how to refit components.
Encouraging feedback loops where operators report and address minor defects before they impact production.
6. Reduce Quality Defects
By this stage, a proactive maintenance culture is established, leading to fewer equipment failures and quality issues. Operators and engineers collaborate to:
Identify and eliminate root causes of defects in the production process.
Reduce variations in equipment performance to improve product consistency.
Implement error-proofing techniques (poka-yoke) to prevent defects.
Enhance overall process stability, ensuring smooth and defect-free operations.
7. OAC Self-Management
The final stage is achieving operator self-management, where teams take full ownership of equipment care and reliability. At this level:
Operators are proactively managing maintenance without constant engineer intervention.
Continuous improvement becomes embedded in the company culture.
Teams independently track performance metrics and refine maintenance standards.
Engineers can focus on innovation and process optimisation, rather than routine breakdown fixes.
Key Success Factors for OAC Implementation
A successful OAC programme requires several critical factors to ensure its effectiveness and sustainability:
Senior Management Support
Commitment from leadership to drive and sustain the programme.
Clear Programme & Project Plan
Well-defined objectives, timelines, and responsibilities.
Performance Tracking & Improvement
Ongoing monitoring to measure success and refine strategies.
Technical Skills Training
Equipping operators with the necessary expertise.
Comprehensive Knowledge Gathering (Pilot)
Using the GRASP© methodology to review and standardise maintenance plans, safety, quality, and cleaning requirements.
Next Steps: How MCP Can Help
MCP offers specialised training and consultancy services to support companies in implementing OAC strategies., such as:
Introduction to OAC – Training for all levels, covering key OAC components and collaboration strategies.
Technical Operator Training – Hands-on training for routine maintenance tasks and fault detection.
OAC Implementation Programmes – A structured approach to adopting OAC with defined milestones and continuous improvement initiatives.
Learn More About OAC
Our comprehensive approach ensures that organisations can effectively adopt OAC and achieve significant improvements in equipment reliability, maintenance efficiency, and overall operational performance.
Implementing OAC is a transformative step toward a more efficient and collaborative workforce. Our detailed eBook provides in-depth insights into best practices, real-world applications, and a roadmap for implementation. You can download your complimentary copy here:
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eBook - Closing Skills Gaps with Operator Asset Care