Autonomous Maintenance vs. Planned Maintenance: Unlocking the Power of TPM in Metal Manufacturing

Whether you're managing CNC machines on the factory floor or coordinating teams in heavy metal manufacturing, Planned Maintenance (PM) is a critical practice that keeps operations running smoothly. As a key pillar of Total Productive Maintenance (TPM), PM helps reduce unplanned downtime, extend equipment life, and control costs.  The Challenge of Unplanned Downtime Unplanned downtime is one of the most significant challenges faced by metal manufacturers. Equipment failures not only disrupt production schedules but also lead to costly repairs and lost revenue. lubrication, inspections, and minor repairs. Unplanned downtime costs industrial manufacturers an estimated $50 billion annually (WSJ/Emerson) . This is where Planned Maintenance (PM) comes into play. PM involves scheduling regular inspections, preventive maintenance tasks, and repairs to address issues before they escalate. It’s a proactive approach that ensures equipment operates reliably and efficiently. The Role of Planned Maintenance in TPM Planned Maintenance (PM) is one of the eight pillars of Total Productive Maintenance (TPM). TPM is a manufacturing strategy designed to optimize equipment reliability, minimize downtime, and enhance product quality. PM focuses on scheduling maintenance activities systematically to prevent unexpected breakdowns. Key Benefits of Planned Maintenance Reduced Unplanned Downtime: Regular inspections help identify issues early Improved Equipment Lifespan: Preventive care extends asset life Enhanced Productivity: Reliable machines keep production lines running smoothly Lower Maintenance Costs: Proactive repairs cost significantly less than emergency fixes Real-Life Example: Aluminum Fabricator in Nashville At a large aluminum fabrication plant in Nashville, Tennessee, a press brake operator implemented Planned Maintenance principles during daily checks: The operator noticed a gradual drop in hydraulic pressure through sensor alerts Reported the issue to the maintenance team The team replaced a worn-out press seal before it failed completely This proactive intervention prevented an unplanned breakdown during a high-demand production period, reducing downtime for the press brake by 50% while improving overall equipment efficiency (OEE) from 70% to 76%. This demonstrates how trained operators can contribute directly to productivity and cost savings. Benefits of Planned Maintenance The impact of Planned Maintenance extends beyond individual success stories. According to a report by McKinsey , operations implementing PM experienced: 30% Maintenance Cost Savings Up to 50% reduction of Unplanned Downtime Additionally, reactive maintenance can cost three to four times more than preventive and planned maintenance (Powerhouse Dynamics) . Maximizing Uptime with Planned Maintenance Operations leaders across the metal manufacturing industry are increasingly adopting Planned Maintenance strategies as part of their TPM programs. By proactively addressing equipment issues before they escalate, manufacturers can achieve: Reduced downtime Improved reliability Enhanced safety Lower costs Learn More For more insights into TPM strategies and how Planned Maintenance supports operational excellence, visit Lean Production’s TPM Framework And that’s your Corvex Connected Workforce Quick Take!

Whether you're managing high-capacity press brakes or automated tube bending machines, workplace safety is paramount in metal manufacturing environments, the following Autonomous Maintenance (AM) guidance will provide insights to enhance workplace safety , reduce hazards, and empower operators to take ownership of equipment care. Why Safety Matters in Metal Manufacturing Metal manufacturing facilities, such as pipe and tube plants serving construction and energy industries, face unique challenges related to workplace safety. Heavy machinery, high temperatures, and complex equipment create risks that require proactive strategies to mitigate. This is where Autonomous Maintenance (AM) comes into play. Key Benefits of Autonomous Maintenance for Safety: Proactive Hazard Prevention: Operators identify and address issues before they escalate. Improved Equipment Reliability: Routine upkeep minimizes unexpected failures that could lead to accidents Enhanced Operator confidence: Empowered operators take ownership of safety The Role of AM in Total Productive Maintenance (TPM) Autonomous Maintenance (AM) is one of the eight pillars of Total Productive Maintenance (TPM). It focuses on empowering operators to perform routine maintenance tasks such as cleaning, inspections, and minor repairs. By fostering a culture of shared responsibility between operators and maintenance teams, AM ensures that equipment operates safely and efficiently. How AM Improves Safety: Early Problem Detection: Operators spot issues like leaks or wear during routine checks. Consistent Equipment Care: Regular cleaning and lubrication prevent deterioration. Structured Training: Operators gain the skills needed to maintain equipment safely Real-Life Example: Pipe and Tube Plant in Bethlehem At a pipe and tube manufacturing plant in Bethlehem, Pennsylvania, an operator noticed unusual vibrations during routine Autonomous Maintenance checks on a tube bending machine. Here’s how AM principles prevented a potential hazard: The operator inspected the hydraulic system and discovered a loose fitting causing fluid leakage—a potential slip hazard. Tightened the fitting and cleaned the area thoroughly. Checked the machine’s safety guards for proper alignment. These proactive actions not only prevented a workplace accident but also avoided damage to critical components that could have led to downtime. By empowering operators through AM training, the plant ensured safer operations and uninterrupted production schedules. The Impact of AM on Workplace Safety According to the Kaizen institute "AM contributes to creating a safer work environment. Operators involved in maintenance activities become more aware of the risks and necessary safety measures. This results in a reduction in accidents and equipment-related injuries."  Driving Safety with TPM Operations leaders across the metal manufacturing industry are increasingly adopting technologies that support TPM initiatives like Autonomous Maintenance. By empowering operators to take ownership of routine maintenance tasks, manufacturers can reduce workplace hazards, improve reliability, and boost productivity. Learn More For more insights into TPM strategies and their benefits for workplace safety, visit: SafetyCulture’s Guide to Total Productive Maintenance Camcode’s Overview of Autonomous Maintenance MaintainX’s Beginner’s Guide to Autonomous Maintenance And that’s your Corvex Connected Workforce Quick Take!

Here at Corvex, we've had many discussions with leaders in welding operations about how Autonomous Maintenance empowers operators to keep their robotic systems running efficiently and safely.

Why Training Is Essential for Autonomous Maintenance Proper training empowers operators to take ownership of equipment care, driving efficiency, safety, and reliability in manufacturing environments. Autonomous Maintenance (AM) equips operators with the skills needed to perform routine maintenance tasks such as cleaning, lubrication, inspections, and minor repairs. However, without proper training, operators may lack the confidence and technical knowledge required to identify issues or perform preventive tasks effectively. Key Benefits of Training for AM Improved Equipment Reliability: Operators learn to detect abnormalities early, preventing breakdowns Enhanced Operator Confidence: Training instills a sense of ownership and responsibility Increased Efficiency: Plants implementing AM training see up to a 10–15% boost in overall efficiency How Training Fits into Total Productive Maintenance (TPM) Training is one of the foundational elements of TPM and is essential for successful implementation of AM. It ensures operators understand their equipment deeply—its components, common issues, and troubleshooting procedures. This knowledge enables them to perform routine maintenance tasks confidently and proactively. Key Skills Developed Through Training 1. Problem Detection: Operators learn to identify emerging issues before they escalate. 2. Technical Knowledge: Comprehensive understanding of machine components and their functions. 3. Maintenance Procedures: Proper cleaning, lubrication, and calibration techniques Real-Life Example: Fabricated Plate Work Plant in Mobile At a fabricated plate work plant in Mobile, Alabama, a plasma cutter operator noticed inconsistent cutting precision during routine AM checks. Here’s how targeted training helped resolve the issue: The operator identified worn consumables causing the problem She replaced the cutting nozzle and cleaned guide rails to remove debris buildup She recalibrated the system to restore cutting accuracy Then she documented findings with photos and shared feedback with the maintenance team to refine inspection protocols These actions prevented production delays and eliminated potential safety hazards like overheating caused by worn components. The Transformative Impact of Autonomous Maintenance Training Investing in operator training is not just an expense—it’s a necessity for effective AM programs. According to the Society for Maintenance and Reliability Professionals ( SMRP ): Facilities implementing AM training programs experience up to a 40% increase in asset lifespan Operators gain confidence, reducing reliance on reactive maintenance Additionally, structured training programs foster a culture of continuous learning and improvement, ensuring operators stay updated with emerging technologies and best practices. Closing Thoughts: Driving Excellence Through Training Leaders in metal manufacturing understand that training is the cornerstone of successful Autonomous Maintenance programs. By equipping operators with the skills needed to maintain their equipment proactively, manufacturers can reduce downtime, improve reliability, and enhance workplace safety. Learn More For more insights into TPM strategies and their benefits, visit Lean Production’s TPM Framework And that’s your Corvex Connected Workforce Quick Take!