Operator Asset Care: An Answer to the Current Skills Shortage
The UK manufacturing industry is facing an acute shortage of maintenance engineers and technicians. Coupled with increasing pressures to optimise production costs - especially with recent changes in National Insurance and minimum wage requirements - companies must find innovative ways to maintain efficiency. One highly effective solution is Operator Asset Care (OAC).
The Role of Operator Asset Care (OAC)
Equipment performance is influenced by multiple factors, and maintenance alone is not enough to optimise costs.
Operation
40-50% Impact
• One best way to operate
• Standard operating procedures
• Preventing failures
• OEE monitoring
• CI activities
• Skills and training
Design
30-40% Impact
• Fit for purpose
• Standardised equipment/ components
• Built-in reliability
• Ease of operation
• Ease of Maintenance
Maintenance
10-30% Impact
• Risk Based Maintenance
• Precision maintenance
• Maintenance plans
• Delivery of plans
• Maintainability - MTTR
• CI activities
• Skills and training
Companies that focus solely on improving maintenance efficiency risk missing out on a significant opportunity for cost reduction. The biggest potential for improvement in existing plants comes from how equipment is operated and maintained by production operators. This is where OAC delivers real value.
OAC requires a collaborative approach involving equipment engineers, production operators, and maintenance teams. By engaging operators in basic maintenance and care of their equipment, businesses can enhance efficiency, reduce downtime, and maximise overall equipment effectiveness (OEE).
How Can OAC Be Implemented?
For OAC to be effective, it requires structured support from both production and maintenance teams. Operators take responsibility for some routine maintenance tasks while ensuring equipment runs at optimal performance levels. OAC has already been successfully implemented in industries such as food and drink and pharmaceuticals, proving its versatility and effectiveness.
OAC vs. TPM vs. Autonomous Maintenance
While often confused with Total Productive Maintenance (TPM) or Autonomous Maintenance (AM), OAC is a modern, flexible approach that extends beyond these concepts:
Like AM, OAC involves operators handling routine maintenance, but it also integrates technology and data-driven insights.
OAC often includes advanced techniques like condition monitoring and digital tools for equipment performance tracking.
It encourages continuous improvement, allowing operators to proactively enhance maintenance processes and optimise performance.
Key Requirements for Successful OAC Implementation
To establish a strong OAC programme, companies must focus on these essential elements:
Training – Operators need thorough training on equipment use, early signs of wear, and basic maintenance techniques.
Standard Operating Procedures (SOPs) – Clear, visual, and well-documented maintenance guidelines are crucial.
Equipment Knowledge – Operators must understand how their equipment works, supported by user manuals and technical documentation.
Collaboration with Maintenance Teams – While operators handle basic maintenance, skilled technicians must be available for complex repairs.
Access to Tools & Technology – Digital checklists, real-time monitoring, and diagnostic tools enhance effectiveness.
Empowerment & Accountability – Operators should have the authority to adjust settings, make minor repairs, or halt production to prevent major failures.
KPIs & Performance Tracking – Establishing metrics such as machine downtime, breakdown frequency, and production loss helps measure OAC success.
Communication & Feedback – A culture of continuous improvement thrives on open discussions between operators, maintenance teams, and management.
Management Support – Strong leadership commitment ensures OAC aligns with business goals and receives necessary resources.
Cultural Shift – Transitioning to OAC requires operators to take greater ownership of equipment maintenance.
Competence Identification – Some operators naturally excel in technical tasks, while others may need extra support. Identifying the right people for upskilling is crucial.
The Benefits of Implementing OAC
Introducing Operator Asset Care delivers multiple advantages, including:
✔ Reduced Production Downtime – Less time lost due to breakdowns and unplanned maintenance.
✔ Enhanced Workforce Skills – Reduces reliance on scarce maintenance resources by upskilling existing employees.
✔ Lower Maintenance Costs – Operators handle routine tasks, freeing maintenance teams for specialised work.
✔ Increased OEE – Improved efficiency and productivity across operations.
MCP Consulting Group offers expert guidance, training, and implementation support for businesses looking to establish an effective OAC programme.
Ready to transform your maintenance strategy? Contact us today!