Mobile Enterprise Asset Management

Autonomous Maintenance (AM): Steps, Why, and Benefits

Published on 
October 15, 2025
 • 
0
 min read
Uma Mahesh

Introduction

Autonomous Maintenance (AM) is transforming how organizations manage their equipment. This strategy empowers operators to take a proactive role in maintaining their machines—reducing breakdowns and improving efficiency.

Autonomous maintenance

Why Autonomous Maintenance Matters

In industries where downtime costs thousands of dollars per hour, Autonomous Maintenance ensures that machines stay reliable and efficient. The principle is simple—“a well-maintained machine is a profitable one.” With AM, operators keep their equipment running smoothly with minimal dependence on maintenance teams.

In this blog, we’ll explore what Autonomous Maintenance means, how to implement it step by step, its key benefits, and how technology—especially mobile maintenance solutions—enhances its success.

What Is Autonomous Maintenance?

Autonomous Maintenance is a system where machine operators handle the basic upkeep of their equipment—tasks like cleaning, lubrication, and inspections. Instead of relying solely on maintenance teams, operators take ownership of their machines.

This boosts both equipment reliability and operator engagement. For instance, when operators check and lubricate their machines after each shift, they prevent unexpected breakdowns and keep production running smoothly.

According to the International Journal of Productivity and Performance Management, organizations adopting Autonomous Maintenance experience a 40% reduction in downtime and a 25% increase in productivity (source: ResearchGate).

8 Steps to Implement Autonomous Maintenance

Implementing Autonomous Maintenance is a structured journey that unfolds in eight steps.

8 steps to implement Autonomous Maintenance

1: Define Roles and Responsibilities

Assign AM tasks to operators who handle the equipment daily. Their operational knowledge helps them understand how machines function. Establish a proactive inspection routine with a clear timeline to minimize unexpected failures.

2: Provide Operators with Targeted AM Task Training

Train operators in cleaning, inspection, lubrication, and minor repairs. This builds confidence, accuracy, and safety awareness. Well-trained operators manage basic upkeep effectively, boosting reliability and equipment life.

3: Begin with a Pilot Machine for Gradual Implementation

Begin with one machine or production line to fine-tune the process. A pilot phase identifies challenges and allows gradual scaling. This approach builds operator confidence and ensures smoother facility-wide adoption.

4: Allocate Sufficient Time to Conduct AM Activities

Give operators dedicated time for Autonomous Maintenance tasks. Treat this as part of their regular responsibilities. Proper scheduling prevents rushed inspections and promotes consistent machine care.

5: Implement Visual Tools for Standardized Maintenance Management

Visual factory tools—color coding, labeling, SOPs, and one-point lessons—simplify maintenance routines. Color-coded lubrication points or visual checklists help operators perform tasks consistently and detect issues early.

6: Utilize Operator Insights for Early Issue Detection

Operators often notice subtle changes in machine behavior before a breakdown occurs. Provide a simple way for them to report issues directly to maintenance teams. This collaboration strengthens the AM process and prevents costly failures.

7: Share Equipment Performance and Health Metrics

Give operators access to performance data and Asset Condition Monitoring metrics. Understanding these KPIs helps them see the impact of AM on overall efficiency and encourages continuous improvement.

8: Monitor and Improve

Review inspection and cleaning data to identify recurring issues. Adjust maintenance schedules accordingly. Continuous monitoring ensures AM evolves as your operations grow.

Benefits of Autonomous Maintenance

Autonomous Maintenance delivers measurable business value.

    • Reduced Equipment Downtime – Early detection and intervention reduce unplanned breakdowns.
    • Extended Equipment Lifespan – Regular cleaning and inspection prevent wear and tear.
    • Higher Productivity – Fewer disruptions mean smoother operations and improved efficiency.
    • Operator Engagement – Operators feel more responsible for performance and develop a deeper understanding of their machines.
  • 4 Tips for Sustaining Autonomous Maintenance

    To keep Autonomous Maintenance effective, focus on long-term consistency.

    1. Provide Ongoing Training – Update operator skills as equipment and technology evolve.
    2. Incentivize Involvement – Recognize operators who excel at maintenance practices.
    3. Integrate Feedback Loops – Encourage regular discussions about challenges and improvements.
    4. Monitor KPIs – Track metrics like downtime, repair cost, and operator performance to refine the process.
  • The Role of Technology in Autonomous Maintenance

    Technology is central to the Future of Maintenance. It makes Autonomous Maintenance smarter and more efficient. Tools like IoT sensors, predictive analytics, and mobile maintenance solutions empower operators to manage assets proactively.

    Predictive Maintenance Software

    Predictive maintenance uses data analytics and sensors to forecast potential failures. This supports AM by identifying issues before they escalate, ensuring better machine health and operational continuity.

    IoT-Enabled Devices

    IoT sensors allow real-time communication between machines and operators. Alerts sent to mobile devices enable quick corrective action—key to effective Autonomous Maintenance.

    Digital Maintenance Platforms

    Centralized digital platforms simplify scheduling, inspections, and reporting. They ensure no maintenance task is missed and give operators a complete view of asset performance.

    Mobile Asset Management Solutions

    A mobile asset management solution provides on-the-go access to maintenance checklists, work orders, and asset data. It enables remote collaboration and faster issue reporting. Operators can easily log findings, attach photos, and update asset conditions—improving decision-making and responsiveness.

    Look for a mobile maintenance solution that integrates seamlessly with ERP systems like Oracle or SAP and works offline. This ensures reliability even in remote locations with limited connectivity.

    Explore Propel Apps' Mobile Asset Maintenance Solution

    Propel Apps’ mobile asset maintenance solution enhances Autonomous Maintenance and overall asset management. Built on Oracle EAM and design thinking, it gives maintenance teams access to:

    • Work orders and asset history
    • Notes, pictures, and location details
    • Real-time collaboration and decision support

    This solution enables organizations to improve plant maintenance efficiency and empower their workforce.

    To learn how Propel Apps can transform your maintenance operations, schedule a free demo today.

    Final Thoughts

    Autonomous Maintenance is more than a maintenance method—it’s a shift in how organizations view equipment management. By empowering operators, you reduce downtime, boost productivity, and extend machine life.

    Following the eight implementation steps and embracing digital tools like predictive maintenance and mobile solutions prepares your organization for the Future of Maintenance. The result? A smarter, more engaged workforce and a more reliable production environment.

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