What are the 7 Steps of Autonomous Maintenance?

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.


Welding operations, especially those using robotic MIG and TIG welders, rely on precision and consistency to meet production demands. 


Autonomous Maintenance equips and enables operators to maximize productivity.  They not only manage routine upkeep, ensuring smooth operations, but they also reduce reliance on reactive maintenance.


Question
Are you familiar with the seven steps of Autonomous Maintenance, and how they can be implemented to benefit welding operations?


Answer
Autonomous Maintenance is a structured process that empowers operators to perform basic care tasks, keeping equipment in top condition. It follows seven key steps.


Step 1 - Increase Operator Knowledge

Operators become the heartbeat of robotic welding, mastering every detail—from the precision of sensors to the movement of nozzles and arms. They don’t just run the machines; they understand them.


A study in Manaus, Brazil, found that implementing Autonomous Maintenance boosted operator knowledge by 39%, empowering them to catch issues before they escalate. This isn’t just about efficiency—it’s about ownership, pride, and ensuring every weld meets the highest standard.


Step 2 - Initial Cleaning and Inspection

Operators take pride in maintaining robotic arms, meticulously cleaning away dirt, grease, and weld spatter that could compromise precision. This isn’t just routine maintenance—it’s a commitment to excellence.


Step 3 - Eliminate Contamination Sources

Operators go beyond surface fixes—they tackle the root causes of contamination, from poorly maintained wire feeders to clogged gas nozzles. By proactively identifying and resolving these issues, they ensure consistent weld quality, reduce downtime, and keep production running at peak performance. 


Step 4 - Set Standards for Lubrication and Inspection

Operators take a proactive role by establishing precise lubrication procedures for robotic joints and conduct thorough inspections of electrical connections, preventing wear and potential malfunctions. 


Step 5 - Conduct Routine Inspections

Through regular checks, operators become the first line of defense against costly breakdowns. By detecting abnormal vibrations or misalignments in the welding arm early, they prevent minor issues from turning into major repairs.


Step 6 - Standardize Visual Maintenance Tools

Color-coded tags and visual guides serve as constant reminders for operators, ensuring no critical maintenance task is overlooked. They help pinpoint exactly when consumables like contact tips or gas diffusers need replacing, streamlining workflows and preventing disruptions. 


Step 7 - Drive Continuous Improvement

Feedback from inspections isn’t just collected—it’s actively used to refine and improve maintenance practices. Every insight helps shape a more efficient and reliable system, allowing operators to stay ahead of potential issues and continuously enhance performance.


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




At a welding facility in Dayton, Ohio

An operator noticed inconsistent wire feeding during an Autonomous Maintenance check of robotic MIG welders.


Following are the seven steps of AM he followed

1

The operator increased his knowledge of how the welder works

2

He cleaned the wire feeder system

3

He inspected for contamination sources

4

He replaced worn components based on established standards

5

He carried out inspection and monitoring

6

He then documented his findings using visual tools

7

He suggested improvements to prevent future issues


Today, high performing operations leaders in the metals industry are diligently deploying technologies that support TPM initiatives like Autonomous Maintenance.   


Learn more about Autonomous Maintenance from the Kaizen Institute.

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The Role of Training in Autonomous Maintenance: Unlocking the Potential of TPM

By info • April 25, 2025
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!

How Autonomous Maintenance Improves Equipment Reliability and Reduces Downtime

By info • April 25, 2025
Whether you’re operating waterjet cutters in aerospace manufacturing or CNC machining centers in metalworking, the following Autonomous Maintenance guidance will provide actionable insights to transform your operations. The Role of Autonomous Maintenance in Equipment Reliability Autonomous Maintenance (AM) empowers operators to take ownership of routine maintenance tasks, such as cleaning, lubrication, and inspections. By decentralizing these activities, AM fosters a culture of accountability and early problem detection, ensuring that equipment operates at peak performance. This proactive approach reduces reliance on reactive maintenance and helps prevent costly breakdowns. Key Benefits of Autonomous Maintenance: Reduced Downtime: Operators identify issues early, preventing unplanned stoppages Improved Equipment Lifespan: Routine care prevents excessive wear and damage Enhanced Safety: Proactive maintenance reduces risks associated with equipment failures While Autonomous Maintenance (AM) focuses on empowering operators to perform daily care tasks, Planned Maintenance (PM) involves scheduled interventions by maintenance teams based on equipment condition and usage data. Together, these pillars of TPM create a balanced approach to reliability and efficiency. Key Differences Autonomous Maintenance: Daily tasks like cleaning, inspections, and minor repairs performed by operators Planned Maintenance: Scheduled activities like part replacements and major repairs handled by maintenance teams Real-Life Example: Aerospace Manufacturer in Spokane At an aerospace manufacturing facility in Spokane, Washington, a waterjet operator implemented Autonomous Maintenance principles to address irregular pressure levels during routine checks. Here’s how the process unfolded: Cleaning Abrasive Feed Lines: This prevented blockages that could have disrupted precision cutting Inspecting Seals for Wear: This ensured optimal machine performance Replacing a Worn Nozzle: This maintained cutting accuracy; critical for aerospace-grade components Documenting Findings: Photos were taken to streamline future inspections and improve nozzle replacement procedures These actions not only maintained cutting precision but also prevented downtime that could have disrupted production schedules The Transformative Impact of Autonomous Maintenance Operations leaders in industries like aerospace and metal manufacturing are increasingly adopting AM initiatives due to their profound impact on reliability and productivity. According to the Kaizen Institute : Facilities implementing AM see up to a 40% reduction in equipment downtime Equipment lifespan increases by up to 50%, significantly lowering long-term costs Moreover, AM fosters employee engagement by empowering operators with the skills and responsibility to maintain their machines effectively. This leads to higher morale, improved safety standards, and enhanced operational efficiency. Driving Excellence with TPM Autonomous Maintenance is not just about reducing downtime—it’s about transforming how manufacturers approach equipment care. By integrating AM into your TPM strategy, you can unlock new levels of reliability, safety, and productivity while fostering a culture of continuous improvement. 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!